New EraUniversity

COLLEGE OF ENGINEERING & ARCHITECTURE

MECHANICAL ENGINEERING DEPARTMENT

Group 3:
Mini-Hydro Power Plant
T 4:00pm-7:00pm

Prepared by:

NICASIO, KHANNIEL D.
MAN-AWIT, SHARMAINE C.
RABANAL, DARYLL RENZ A.
LAGUITAN, JEREMY
OPOG, MARLONE I.
PACIO, LANCE
QUERIDO, VELMORE JOHN
QUIROS, KEITH VINCENT

Submitted to:
ENGR. ERWIN T. STA. MARIA
Instructor
 TABLE OF CONTENTS

I. INTRODUCTION

II. DESIGN PROBLEM

III. OPERATING PARAMETERS

A.) GEOGRAPHIC MAP

B.) ENERGY LOADS

C.) OTHER ASSUMPTIONS NEEDED

IV. REFERENCES

V. DESIGN CALCULATIONS

VI. CONCLUSION AND RECOMMENDATIONS

I. INTRODUCTION

Electrical power has become an essential factor in the daily lives of modern

people. This power can be produced in many ways possible. However, due to an

increasing demand, the production needs to level with or surpass the demand. Trying to

surpass the growing demand may lead to an increase in environmental pollution, with

some power-generating plants that cause adverse effects to the environment. Increasing

power production using alternative sources of energy can help with the environmental

pollution.

Hydro power generation can be planned on small scale on existing small water

channels. The basic principle of hydropower is for water to be piped from a certain

altitude to a lower altitude, the resulting water pressure can be used to do work. It

considers the design and installation of mini hydropower plant. The most important

aspect of environment is also stated so that the project has minimal negative impact on

the environment.

Electricity may not have been utilized to some areas yet, but water resources that

could suffice enough energy to produce electricity are available. These water resources

could also be used not just in power generation, but also for other purposes. With these,

areas that don’t have sufficient power but has access to nearby rivers can construct a

hydro power plant of their own and benefit from it.

This paper can be well utilized for planning in and around rural areas. This paper

presents the design details of a run-of-river mini hydro project with a 600 kW capacity

including all its aspects: designed head, designed discharge, machine ratings, power

house dimensions etc.

Nomenclatures:

Hgr – Gross Head (m)

Hn – Net head (m)

P – Power (W)

ρ – Density (kg/m3)

g – Gravitational Acceleration (m/s2)

Q – Flow rate (m3/s)

Lpst – Length of Penstock (m)

Dpst – Diameter of Penstock (m)

nQE – Specific Speed (-)

n – Rational Speed (s-1)

E – Specific Hydraulic Energy (kJ/kg)

nmax – Maximum Runner speed (s-1)

De – Runner Diameter (m)

Di – Hub Diameter (m)

HLD – Darcy Weisbach Head Loss (m)

HLH – Hazen William Head Loss (m)

hLin – Head Loss at inlet (m)

hLV – Head Loss at valves (m)

HTL – Total Head Loss (m)

C – Design Coefficient (-)

K – Flow Coefficient (-)

II. DESIGN PROBLEM

A small community is in need of power for their daily living and livelihood within

a mountainous region where water is abundant from a nearby river with the data given

below, design a small or mini-hydro power plant that will suit their requirements:

Existing power load from a Diesel

Generating unit (intermittently None
running due to long service life)

Current Daily Demand 600 kW

Projected demand increase in the 3%

next 10 years

FLOW
MONTH
RATE
January 14.32
February 13.30
March 14.95
April 9.27
May 9.20
June 9.90
July 14.39
August 17.23
September 16.56
October 22.03
November 21.76
December 15.05

Table 1. Average Flow for 24 hours (m3/s)

This table shows the average flow rate for every month of a whole year. A

condition of a 10% decrease in water flow for every 30 m descent (refer to the map)

should be considered in the calculations.

 Flow Rate
25

20

15

10

Figure 1. Average monthly flow fluctuations.

Plotting the monthly data flow rate, the lowest flow records can be observed in

the months of summer (April, May, June). The flow starts to increase afterwards in the

wet season. The highest flow was seen in the month of October.

SECTOR DISTRIBUTION OF LOAD PERCENTAGE

Residential 100%
Industrial 0%
Commercial 0%

Table 2: Load Shares of Different Sectors

This table represents the different sectors and their distribution of loads. As

shown in the table, 100% of the load in the small community comes from the residential

sector.
Figure 3. Proposed Arrangement of Elements for the Mini Hydro Power Plant
III. GIVEN PARAMETERS

A. Geographic map

Figure 2. Topographic data of the area where the red box indicates the small community and the river flows from right to left.
A.) Energy loads

Figure 4. Daily Demand Profile

Figure 4 shows the hourly demand energy loads in the small community.

The blue and red line indicates the demand for weekdays and demand for the

weekends, respectively. The y axis represents the demand load (kW) while the x axis

represents the hour. Based on the graph, the community has a significant increase in

load at around 7:00 am - 9:00 am. The weekday peak demand period ranges from

9:00 am - 2:00 pm. During these period, the hydropower plant needs to generate

power the will adequately supply or exceed the given peak demand.

B.) Other assumptions needed

The hydropower plant system is designed as a run-off-river wherein the flow

of water at point (insert point) is diverted with the use of a weir. The powerhouse

was determined to be located below point 14.

 Assumptions presented below will be used for design calculations.

 Water is incompressible

 The calculations for the weir will be based on the minimum flow rate of 9.2

m3/s

 Water temperature is constant at 20oC

 Constant Moody Friction Factor per pipe section

IV. REFERENCES

"Layman's guidebook on how to develop a small hydro site", Published by the European
Small Hydropower Association (ESHA), Second edition, Belgium, June, 1998.

"Design of Hydraulic Turbines Journal by Q.H. Nagpurwala"

"Manuals and Guidelines for Micro Hydro Power Development in rural Electrification,
Volume 1 by Department of Energy, June 2009"

"A text Book of Fluid Mechanics and Hydraulic Machines by Bansal"

V. DESIGN CALCULATIONS

The following calculations are specifically arranged as some data are prerequisite of

other data.

Flow rate design

Flow rate of 2.74 m3/s was used in the calculations for the power rating. With the power

being given, the gross head and the flow rate must correspond with one another.

Headwork analysis

The analysis for the altitude was done using Figure 5 and using arithmetic operations,

the gross head for the hydropower plant can be computed. Using points 10 and 14 shown

in Figure 6, the gross head for the hydropower plant was computed. Calculations for the

gross head are as follows:

Site Altitude = 24m

Point 10 = 68 m

Point 14 = 65 m

Forebay altitude = (68 + 36) / 2 = 52m

Gross Head (Hgr) = Forebay altitude – Site Altitude

Gross Head (Hgr) = 52m – 24m

Gross Head (Hgr) = 28m

The given altitude in point 14 was assumed to have an increase of 2 meters in order to

consider the inaccuracy of length measurements in the map.

Penstock analysis

Based on the scale of 2 cm: 2 km, the length of the weir to powerhouse (vertical and

horizontal) was plotted in the given map. Proposed distances are presented below in

form of triangles for better analysis.

 Figure 5. Distance of Weir to Powerhouse

Figure 5 shows the vertical and horizontal distance of the weir to the powerhouse. The

hypotenuse (diagonal length) and the angle were computed using trigonometric

formulas. Computations are presented below:

Using Pythagoras Theorem

c=
where:
c = diagonal distance from weir to powerhouse
a = 65 m
b = 50 m
Substituting:
c=
c = 82 m
Computing for the angle:
Tan ø = 50/65

Ø = 37.57° say 38°

 Figure 6. Distance of Forebay to Powerhouse

With the given angle, the horizontal and diagonal distance from the forebay to the

powerhouse can be computed. The diagonal distance can be classified as the length of

the penstock, since the penstock is connected and located between the forebay and the

powerhouse. Calculations are presented below:

Tan (38) = 28/(horizontal distance)

Horizontal distance = 35.8 m

Sin (38) = 27/(diagonal distance)

Diagonal distance = 45.48 m

The diagonal distance or the length of penstock, as computed, is 45.48 m. However,

accounting for the bending and misdirection of the pipes, the designed length of the

penstock was increased to 50 m.

 Figure 7. Dimensions of penstock

The division of the lengths of penstock was designed based on the assumed topography

of the area, as the topographic data was only limited to one point of view (top view).

Lpst = 18m + 12m + 20 m

Lpst = 50 m

Intake and Weir

*The calculations for the weir are placed here because data for penstock and design

flow are needed*

A flow of 9.2 m3/s was used in the calculations of the weir. The lowest flow rate was

chosen in order to compensate for the water flow variation. Bazin's formula was used in

the computations for the dimensions of the weir. The design Q for the turbine is

2.736m3/s, as indicated in the flow rate analysis. Based on the given condition (10%

decrease in water flow for every 30 m), a formula was established for the calculation of

the flow rate in the weir.

Qweir =
Using data from penstock analysis, the diagonal distance of weir to powerhouse is 82m.

Getting the ratio of distances to calculate for the %increase in flow:

Ratio of distances = 82 / 30
= 2.733

Multiplying it by the 10% increase:

%increase in flow = 2.733(10)

= 27.33% is the %increase of the flow of Qdesign to Qweir

Substituting the computed data in the established formula:

Qweir =

Qweir = 3.767 m3/s

Figure 8. Flow balance for the weir

The figure shows the flow rate for every sector, which is composed of the flow rate of

the river (indicated as Qmay), the flow rate going to the channel (indicated as Qweir)

and the remaining flow rate (indicated as Q only). Solving for the remaining flow rate or

the flow rate that will flow out of the weir:

Q = Qmay - Qweir
 = 9.2 = 3.767

= 5.433 m/s

Based on Bazin's Formula from A Text Book of Fluid Mechanics and Hydraulic

Machines pp. 370:

Where:

gravitational constant

height of the water over the weir, correspondence between H & L

width

Assuming the head of the weir is 1m,

= .408

Substituting to Bazin's formula

Penstock diameter

The diameter of the penstock can be computed using many relations. However, since the

flow rate and the head were given earlier, two relations were chosen for the calculation.

Based on International Journal of Energy and Power Engineering 2015 pp (insert pages):
Using USBR 1986 relation,

Dpst1 = (1.517 x Q0.5 ) / (Hgr0.25) [m] (eq.2)

Dpst1 = (1.517 x 2.70.5 ) / (280.25)
Dpst1 = 1.09 m

Using Fahlbusch 1987 relation,

Dpst2 = (1.12 x Q0.45) / (Hgr0.12) [m] (eq.3)

Dpst2 = (1.12 x 2.70.45) / (270.12)
Dpst2 = 1.18 m
Getting the average of the two relations,
Dpst = (1.08m + 1.17 m)/(2)
Dpst = 1.1 m

Computation for the net head

Head loss calculations are needed for the computation of the net head. The head loss

includes losses at penstock and other minor losses. The following calculations for the

losses and the net head are presented below.

Darcy Weisbach Head Loss:

HLD = f x x [m] (eq.4)

Where:
f = friction factor
V = Velocity
The velocity can be established with the following equation:
V=Q/A [m/s] (eq.5)
V = Q / [(π x Dpst2) / (4)] [m/s] (eq.6)
V = (2.7 m3/s) / [(π x 1.12) / (4)]
V = 2.9 m/s

Substituting the velocity to the equation:

HLD = .01 x x [m] (eq.7)

HLD = 0.2 m

Hazen William Head Loss

HLH = (10.76 x Lpst x Q1.85) / (C1.85 x Dpst4.8655) [m] (eq.8)
Where:
C = design coefficient = 100
HLH = (10.76 x 50 m x 2.7 1.85m3/s) / (1001.85 x 14.8655)
HLH = 0.40 m

Head Loss at inlet:

hLin = k x (V2 / 2 x g) [m] (eq.9)
Where:
k = flow coefficient = 0.5
hLin = 0.5 x [(2.9 m/s)2 / 2 x (9.81 m/s2)]
hLin = 0.21 m

Head Loss at valve:

hLV = k x (V2 / 2 x g)
Where:
k = flow coefficient = 0.05
hLv = 0.05 x [(2.9 m/s)2 / 2 x (9.81 m/s2)]
hLv = 0.021 m

Head Loss at Bending:

hLB = k x (V2 / 2 x g)
Where:
k = flow coefficient = 0.13

hLB = 0.13 x [(2.9 m/s)2 / 2 x (9.81 m/s2)]

hLB = 0.06 m
 Total head loss:
HTL = [(HLD + HLH) / 2] + hLV + hLin + (hLB x 2) [m] (eq.10)
HTL = [(0.2 m + 0.40 m) / 2] + 0.021 m + 0.21 m + (0.06 x 2)
HTL = 0.6 m

Net Head:
Hn = Hgr - HTL [m] (eq.11)
Hn = 28 m – 0. 6 m
Hn = 27.4 m

Anchor Blocks

Weight of water per meter of pipe

WWT = Ww1 + Ww2 + Ww3

WWT = (138.2 + 92.70 + 153.46) kN

WWT = 383.73 kN

Weight of penstock

Where:

= yield strength of steel(iron) =

D = Diameter of penstock = 1m

e = thickness = .01m

The vertical component of the weight to be supported, in kN, has a value of:
 Therefore the maximum length between supports is given by the equation:

Power Rating Computation

With a given demand of 600 kW and a projected increase of 3%:

600 kW (0.3) = 618 kW

The small community needs will need 618 kW of power when future projections are

included. Therefore, the calculated power must reach or exceed the power demand.

Based on Layman's Handbook page 141:

Power (P) = ρ x g x Hn x eff x Q [W] (eq.1)

Where:
ρ = water density = 998 kg/m3
g = gravitational constant = 9.81 m/s2
Hn = Net Head = 27.4 m
eff = turbine efficiency = 0.92
Q = water flow rate = 2.7 m3/s

Calculating for the power with the given data above:

P = (998 kg/m3)(9.81 m/s2)(27.4 m)(0.92)(2.7m3/s)

P = 675,017 W or 675 kW is generated power output based on the theoretical

data given above. This power will still account for the projected demand increase

for the next ten years, which was solved earlier.

Turbine Selection

Power = 0.67 MW
Q = 2.7 m3/s
Hgr = 28 m

Figure 9. Turbine Selection Chart

With the following parameters given, the type of turbine can be projected using Figure_.

By plotting the head, the flow, and the power, the established turbine that is to be used is

Kaplan Turbine.
 Figure 10. Heads of a Kaplan Turbine

Specific Speed

is a dimensionless parameter and characterizes the hydraulic properties of a turbine in

terms of speed and discharge capacity.

The specific speed is defined as:

nQE = (n x Q0.5) / E3/4

Where:

E = Specific Hydraulic Energy

n = rational speed of the turbine

The specific hydraulic energy of machine can be established with the following
equation:

E = Hn x g
E = (27.4 m) (9.81 m/s2) = 268.7 kJ/kg

Due to statistical studies of schemes, F. Schweiger and J. Gregory established the

following correlation between the specific speed and the net head for Kaplan turbines:
 nQE = 2.294 / Hn0.486

(Based on Correlation by F. Schweiger and J. Gregory)

Substituting the net head in the formula,

nQE = 2.294 / (27.45)0.486

nQE = 0.46 say .5

Rational Speed Computation

n = (nQE x E 3/4)/ Q0.5
n = (0.5 x 268.73/4)/( 2.70.5)
n = 20s-1

This value of the rational speed, 20s-1, is optimal because it is synchronous to the

generator speed. Thus, the turbine can be directly coupled to it. Based from Layman's

guidebook on how to develop a small hydro site, pp. 180:

Table 3: Generator Synchronization Speed

Table 3 gives the synchronous speeds (in the unit min-1) which the runner should reach

to connect it directly to the generator.

Runaway Speed

It is the max speed which the turbine can theoretically attain. It is achieved during load

rejection. It is achieved during a load rejection. Depending on the regulation of the

Kaplan turbine, the following guidelines can be used to determine the runaway speed

based on Design of the runner of a Kaplan turbine for small hydroelectric power plants

by Jaakko Mattila:

Table 4. Runaway Speed

The turbine is supposed to work double regulated. Hence, a maximum runaway speed is:

nmax = 3.2 x n
nmax = 3.2 x 20 = 64s-1

Runner Diameter

Based on Design of Hydraulic Turbines by Q.H. Nagpurwala, the runner diameter De

can be calculated using the following equation:

De = (84.5) (0.79 +1.602 x + nQE) x [(Hn0.5)/(60 x n)]

De = (84.5) (0.79 +1.602 x 0.5) x [(27.40.5)/(60 x 20)]
De = 0.59 m

Hub Diameter

Based on Design of Hydraulic Turbines by Q.H. Nagpurwala, the hub diameter De can

be calculated using the following equation:

Di = [(0.25) + (0.0951/nQE)] x (De)

Di = [(0.25) + (0.0951/0.5)] x (0.59 m)

Di = 0.26 m
Specific Speed

Based on Design of Hydraulic Turbines by Q.H. Nagpurwala, the Ns can be calculated

using the following equation:

Ns = (n x Q.5) / (Hn 3/4)

Ns = (1200 x 2.7.5) / (27.4 3/4)

Ns = 165.77

Cavitation

The suction head Hs is the head where the turbine is installed; if the suction head is

positive, the turbine is located above the trail water; if it is negative, the turbine is

located under the trail water. The suction head can be calculated using the following

equation:

Hs = [(Patm – Pv) / (ρ x g)] + [(V2) / (2 x g)] – σ x Hn

Patm = 101.325 kPa = 101325 Pa

Pv = 17.5 Torr = 2.33 kPa = 2330 Pa

Table 5. Vapor Pressure Water Based on Temperature

 σ =(1.5241 x nQE1.46) + [(V2) / (2 x g x Hn)]

σ =(1.5241 x 0.50.46) + [(2.92) / (2 x 9.81 x 26.21)]

σ = .57

Hs = [(101325 – 2330) / (1000 x 9.81)] + [(2.92) / (2 x 9.81)] – .57 x 26.21

Hs = -4.42 m (The turbine is below the tail water)

Blade Parameters

Based on Design of Hydraulic Turbines by Q.H. Nagpurwala, the angle of attack can be

calculated using the following equation:

De = .5864
Di = .26
Ns = 165.7735
n = 20
Q = 2.7359 m3/s
Hn = 27.392 m
H1 = 2.1935
H2 = 3.2934

@ De = .59
Part 1
u = π*n*de
= π*20*.5
u = 37.07 m/s

= H1*g/u
= 2.1935*9.81/37.07
= 0.58 m/s

= H2*g/u
 = 3.2934*9.81/37.07
= 0.87 m/s

Part 2
Wu1 = Cu1-u
= 0.58-37.07
Wu1 = -36.4903 m/s

Wu2 = Cu2-u
= 0.87 - 37.07
Wu2 = -36.1993 m/s

Wm = Q/A∞
where: A∞ = π*(De2-D12)/4 = π*(.592-.262)/4 = .2203
= 2.75/.2203
Wm = 12.419 m/s

Wu∞ = Wu1+Wu2/2
= -36.4903+(-36.1993)/2
Wu∞ = -36.3448 m/s

Part 3
W1 = √Wu12+wm2
= √-36.49032+12.41872
W1 = 38.5457 m/s

W2 = √Wu22+wm2
= √--36.19932+12.41872
W2 = 38.2703 m/s

W∞ = √Wu∞+Wm2
= √-36.34482+12.41872
W∞ = 38.4079 m/s

= arcos*( Wu∞/ W∞)

= cos-1(-36.3448/38.4079)
= 161.1351°

AOA = (180°- )
= (180°-161.1351°)
AOA = 18.8649°

@ De = .27-.1 = .49

Part 1

u = π*n*de
= π*20*.49
u = 30.7876 m/s

= H1*g/u
= 2.1935*9.81/30.7876
= 0.6869 m/s
= H2*g/u
= 3.2934*9.81/30.7876
= 1.0494 m/s

Part 2
Wu1 = Cu1-u
= 0.6989-30.7876
Wu1 = -30.0887 m/s

Wu2 = Cu2-u
= 1.0494-307876
Wu2 = -29.7382 m/s
Wm = Q/A∞
where: A∞ = π*(De2-D12)/4 = π*(.492-.262)/4 = .1355
= 2.75/.1355
Wm = 20.194 m/s

Wu∞ = Wu1+Wu2/2
= -30.0887+(-29.7382)/2
Wu∞ = -29.9134 m/s

Part 3
W1 = √Wu12+wm2
= √-30.08872+20.1942
W1 = 36.2371 m/s

W2 = √Wu22+wm2
= √-29.73822+20.1942
W2 = 35.9466 m/s

W∞ = √Wu∞+Wm2
= √-29.91342+20.1942
W∞ = 36.0917 m/s

= cos-1*( Wu∞/ W∞)

= cos-1(-29.9134/36.0917)
= 145.9775°

AOA = (180°- )
= (180°-145.9775°)
AOA = 34.02247°
@ De = .47-.09 = .4
Part 1
u = π*n*de
= π*20*.4
u = 25.1327 m/s

= H1*g/u
= 2.1935*9.81/25.1327
= .8562 m/s

= H2*g/u
= 3.2934*9.81/25.1327
= 1.2855 m/s

Part 2
Wu1 = Cu1-u
= 0.8562-25.1327
Wu1 = -24.2766 m/s

Wu2 = Cu2-u
= 1.2855-25.1327
Wu2 = -23.8472 m/s

Wm = Q/A∞
where: A∞ = π*(De2-D12)/4 = π*(.42-.262)/4 = .0726
= 2.75/.0726
Wm = 37.6997 m/s

Wu∞ = Wu1+Wu2/2
= -24.2766+(-23.8472)/2
Wu∞ = -24.0619 m/s
Part 3
W1 = √Wu12+wm2
= √-24.27662+37.69972
W1 = 44.84 m/s

W2 = √Wu22+wm2
= √-23.84722+37.69972
W2 = 44.609 m/s

W∞ = √Wu∞+Wm2
= √-24.06192+37.69972
W∞ = 44.7241 m/s

= cos-1*( Wu∞/ W∞)

= cos-1(-24.0619/44.7241)
= 122.5481°

AOA = (180°- )
= (180°-122.5481°)
AOA = 57.4519°

@ De = .38-.11 = .29
Part 1
u = π*n*de
= π*20*.29
u = 18.2212 m/s

= H1*g/u
= 2.1935*9.81/18.2212
= 1.1809 m/s
 = H2*g/u
= 3.2934*9.81/18.2212
= 1.7731 m/s

Part 2
Wu1 = Cu1-u
= 1.1809-18.2212
Wu1 = -17.0403 m/s

Wu2 = Cu2-u
= 1.7731-18.2214
Wu2 = -16.4481 m/s

Wm = Q/A∞
where: A∞ = π*(De2-D12)/4 = π*(.292-.262)/4 = .013
= 2.75/.013
Wm = 211.1185 m/s

Wu∞ = Wu1+Wu2/2
= -17.0403+(-16.4481)/2
Wu∞ = -16.7442 m/s
Part 3
W1 = √Wu12+wm2
= √-17.04032+211.11852
W1 = 211.8051 m/s

W2 = √Wu22+wm2
= √-16.44812+211.11852
W2 = 211.7583 m/s
W∞ = √Wu∞+Wm2
= √-16.74422+211.11852
W∞ = 211.7815 m/s

= cos-1*( Wu∞/ W∞)

= cos-1(-16.7442 /211.7815)
= 94.5347°

AOA = (180°- )
= (180°-94.5347°)
AOA = 85.4653°

@ De = .26
Part 1
u = π*n*de
= π*20*.26
u = 16.3363 m/s

= H1*g/u
= 2.1935*9.81/16.3363
= 1.3172 m/s
= H2*g/u
= 3.2934*9.81/16.3363
= 1.9777 m/s

Part 2
Wu1 = Cu1-u
= 1.3172 -16.3363
Wu1 = -15.0191 m/s

Wu2 = Cu2-u
= 1.9777-16.3363
Wu2 = -14.3586 m/s
Wm = Q/A∞
where: A∞ = π*(De2-D12)/4 = π*(.262-.252)/4 = 0
= 2.75/0
Wm = 0 m/s

Wu∞ = Wu1+Wu2/2
= -15.0191 + 1.156/2
Wu∞ = -14.6888 m/s

Part 3
W1 = √Wu12+wm2
= √-15.01912+02
W1 = 15.0191 m/s

W2 = √Wu22+wm2
= √-14.35862+02
W2 = 14.3586 m/s

W∞ = √Wu∞+Wm2
= √-14.68882+02
W∞ = 14.6888 m/s

= cos-1*( Wu∞/ W∞)

= cos-1(-14.6888/14.6888)
= 180°

AOA = (180°- )
= (180°-0°)
AOA = 0°
 Table 6. Angle of Attack in 5 radial Location

Spiral Casing and Draft Tube

Based on Guidelines on Micro Hydro Power Plant by Siervo Lugaresi, 1976, the steel

spiral case and draft tube dimensions can be use by the following equations:

Ns = 165.7735, De = Dm = 0.5863

A= Dm * 0.4 * Ns0.2

= 0.5863 * 0.4 * 165.77350.2 = 0.6517 meters

B = Dm (1.26 + 3.79x10-4 * Ns)

= 0.5863 (1.26 + 3.79x10-4 * 165.7735) = 0.7755 meters

C = Dm (1.46 + 3.24x10-4 * Ns)

= 0.5863 * (1.46 + 3.24x10-4 * 165.7735) = 0.8874 meters

D= Dm (1.59 + 5.74x10-4 * Ns)

 = 0.5863 * (1.59 + 5.74x10-4 * 165.7735) = 0.988 meters

E = Dm (1.21 + 2.71x10-4 * Ns)

= 0.5863 * (1.21 + 2.71x10-4 * 165.7735) = 0.7357 meters

F = Dm (1.45 + )

= 0.5863 (1.45 + ) = 1.1053 meters, r = 0.55265 meters

G= Dm (1.29 + )

= 0.5863 (1.29 + ) = 0.9035 meters, r = 0.45175 meters

H= Dm (1.13 + )

= 0.5863 (1.13 + ) = 0.7751 meters, r = 0.38755 meters

I = Dm (0.45 + )

= 0.5863 (0.45 + ) = 0.1513 meters

L = Dm (0.74 + 8.7x10-4 * Ns)

= 0.5863 (0.74 + 8.7x10-4 * 165.7735) = 0.5184 meters, r = 0.2592 meters

M = Dm / (2.06 – 1.2x10-3 * Ns)

= 0.5863 / (2.06 – 1.2x10-3 * 165.7735) = 0.315 meters, r = 0.1575 meters

N= Dm (2 – 2.14x10-6 * Ns)

= 0.5863 (2 – 2.14x10-6 * 165.7735) = 1.1723 meters

O= Dm (1.4 – 1.67x10-5 * Ns)

= 0.5863 (1.4 – 1.67x10-5 * 165.7735) = 0.8191 meters

P = Dm (1.26 - )

= 0.5863 (1.26 - ) = 0.6809 meters, r = 0.34045 meters

Q= Dm (0.66 - )

= 0.5863 (0.66 - ) = 0.3218 meters

R = Dm (1.25 – 7.98x10-5 * Ns)

= 0.5863 (1.25 – 7.98x10-5 * 165.7735) = 0.7251 meters

S = Dm (4.26 - )

= 0.5863 (4.26 - ) = 3.2103 meters

T = Dm (1.2 – 5.12x10-4 * Ns)

= 0.5863 (1.2 – 5.12x10-4 * 165.7735) = 0.7533 meters

Z = Dm (2.58 + )

= 0.5863 (2.58 + ) = 1.8757 meters, L = 0.93785 meters

FORMULAS

A= Dm * 0.4 * Ns0.2

B = Dm (1.26 + 3.79x10-4 * Ns)

C = Dm (1.46 + 3.24x10-4 * Ns)

D= Dm (1.59 + 5.74x10-4 * Ns)

E = Dm (1.21 + 2.71x10-4 * Ns)

F = Dm (1.45 + )

G= Dm (1.29 + )

H= Dm (1.13 + )

I = Dm (0.45 + )

L = Dm (0.74 + 8.7x10-4 * Ns)

M = Dm / (2.06 – 1.2x10-3 * Ns)

N= Dm (2 – 2.14x10-6 * Ns)

O= Dm (1.4 – 1.67x10-5 * Ns)

P = Dm (1.26 - )

Q= Dm (0.66 - )

R = Dm (1.25 – 7.98x10-5 * Ns)

S = Dm (4.26 - )

T = Dm (1.2 – 5.12x10-4 * Ns)

Z = Dm (2.58 + )
Letter Value

A 0.6517 meters

B 0.7755 meters

C 0.8874 meters

D 0.988 meters

E 0.7357 meters

F 1.1053 meters

G 0.9035 meters

H 0.7751 meters

I 0.1513 meters

L 0.5184 meters

M 0.315 meters

N 1.1723 meters

O 0.8191 meters

P 0.6809 meters

Q 0.3218 meters

R 0.7251 meters

S 3.2103 meters

T 0.7533 meters

Z 1.8757 meters

Table 7. Spiral Casing Dimensioning

Generator Sizing

Important points in the Selection of Generating Units

 The number and sizes of the units should be so selected that they approximately fit the

annual load curve of the station.

 The units should be preferably of different capacities to meet the load requirements.

Although use of identical units (i.e., having same capacity) ensures saving* in cost, they

often do not meet the load requirement.

 The capacity of the plant should be made 10% to 15% more than the maximum demand

to meet the future load requirements.

 There should be a spare generating unit so that repairs and overhauling of the working

units can be carried out.

 The tendency to select a large number of units of smaller capacity in order to fit the load

curve very accurately should be avoided. It is because the investment cost per kW of

capacity increases as the size of the units decreases.

Source: “CHAPTER 3 OF VARIABLE LOAD ON POWER STATIONS, PP. 60-61”

In the selection of generator size, the current demand load is 600 kW but since there is

three percent (3%) increase in next ten (10) years which will yield 618 kW the one that is

considered was the latter so that future load requirement is met. Based on the “CHAPTER 3 OF

VARIABLE LOAD ON POWER STATIONS, PP. 60-61”, the plant should be 10% to 15%

more than the maximum demand for future load expansion. Also in actual, based on

“Generation, Distribution, and Utilization of Electrical Energy by C.L. Wadhwa page 77”, a

generator that is rated 618 kW is may not generate exact 618 kW because plant use factor is not

100% in real. The demand after ten (10) years is 618 kW, assuming ten percent (10%) increase
then the plant capacity would be rated 680 kW. According to “MINI-HYDRO SYSTEMS

USING INDUCTION GENERATORS” by Norris Eaton, Faculty of Engineering and Applied

Science Memorial University of New Foundland, July 1997, the rating of the induction machine

in generator mode is normally taken to be the HP of the motor expressed in kW, thus a 680 kW

generator requires a standard 912 900 HP motor. Usual rating of generators is in kVA so using

a power factor of 0.8 the rating of a 900 HP motor will be 850 kVA generator.

In hydropower plants, the induction or synchronous generators are used. However, in

small hydropower plants, induction generators are the most common choice and size of the

generator is determined by the power of the turbine.

Choosing an induction generator for use in a small hydropower plant has its pros and

cons. Induction generators can be used in island operation or better in parallel with bigger power

systems, because the electricity grid controls their voltage and frequency, while reactive

compensating capacitors are used for correction of the power factor. Some other advantages of

using an induction generator are:

 They are less expensive than synchronous machines.

 They are built simple and robust.

 They are less susceptible to damage and very reliable.

 If connected to a large grid, they don’t need a voltage regulator.

Main problem of induction generators is that they need reactive power, which is absorbed

from the grid, in order to magnetize the generator and generate power.

Drive System

The drive system couples the turbine to the generator. At one end, it allows the turbine to

spin at the velocity that delivers the best efficiency. At the other end, it drives the generator at the
velocity that produces correct voltage and frequency (frequency applies to alternating current

circuits only). When the turbine and the generator operate at the same speed and can be placed so

that their shafts are in line, direct coupling is the right solution with 1:1 ratio between the turbine

and generator; virtually no power losses are incurred and maintenance is minimal. Turbine

manufactures will recommend the type of coupling to be used, either rigid or flexible although a

flexible coupling that can tolerate certain misalignment is usually recommended. This is possible

for many sites, but not for all head and flow combinations. In many situations, especially with

AC systems, it is necessary to adjust the transfer ratio so that both turbine and generator run at

their optimum (but different) speeds. This type of drive system uses gears, chains, or belts each

of which introduces additional efficiency losses into the system. Belt systems tend to be more

popular because of their lower cost.

In this design, direct drive will be the best choice due to its high efficiency and easy

maintenance. Since the turbine speed is 900 rpm the generator rpm should also be 900 rpm.

Below are the pertinent data of the generator needed for the Mini-hydroelectric power plant.

MATERIAL AND EQUIPMENTS SPECIFICATION

INDUCTION GENERATOR
RATED POWER : 850 kVA (900 HP motor)
SYNCHRONOUS SPEED : 1200 RPM
VOLTAGE : 4,160 V
AMPERAGE : 210.5 AMPS
PHASE :3
FREQUENCY : 60 HZ
DUTY CYCLE : CONTINUOUS-USE RATED
SERVICE FACTOR : 1.15
MANUFACTURER : WORLD WIDE ELECTRIC
FRAME SIZE : 6810
FRAME MATERIAL : CAST IRON
ENCLOSURE TYPE : TEFC
BEARINGS : BALL
MOUNTING TYPE : FOOT-MOUNTED
CONNECTION BOX : SIDE
SHAFT TYPE : SMOOTH-SHAFT W/ 1.25 X 1.25 KEY
SHAFT DIAMETER : 4.75’’
SHAFT HEIGHT (FROM BASE) : 17’’
OVERALL LENGTH : 87.7’’
OVERALL HEIGHT : 40.9’’
WEIGHT : 8,820 LBS (3,999.87 KG)
LXWXH : 87.70’’ X 54.50’’ X 40.90’’ (222.76 X
138.43 X
103.89 cm)

SELECTION OF GENERATOR SWITCHGEAR

Hydropower plants place very special demands on the generator switchgear when

compared with other types of power station, especially in terms of frequent switching operations,

load switching and easy, flexible retrofitting. Vacuum circuit breakers, which are becoming

highly preferred for this kind of application, offer an ideal solution to fulfill these special

requirements reliably and efficiently.

In power plants, generator switchgear will ensure dependable synchronization and

maximum operating reliability. Installed between the generator and the transformer, the

switchgear can synchronize various quantities like frequency, voltage, and phase with the

network.
 The generator circuit breaker and associated isolating disconnect switches are used to

connect and disconnect the generator to and from the power system. The generator circuit

breaker may be located on either the low-voltage or high-voltage side of the generator step-up

transformer. In some cases, the generator is connected to the system by means of circuit breakers

located in the switchyard of the generating plant. The generator circuit breaker may be of the oil

filled, air magnetic, air blast, or compressed gas insulated type, depending on the specific

application. The circuit breaker is closed as part of the genera tor synchronizing sequence and is

opened (tripped) either by operator control, as part of the automatic unit stopping sequence, or by

operation of protective relay devices in the event of unit fault conditions

Selection of Transformer

Step-up Transformer (Power Transformer)

When the generator produces power at 4160V, the transformer increases this voltage to as

high as 132 kV and up. Transformer is necessary in very long transmission systems and this is

because high voltage is needed when transmitting the power to reduce the current. Low current

brings down losses due to the resistance of conducting wires. Inversely, when the voltage is low

during the transmission the power, losses would be high that’s why voltage is increased.

Transmission Line Voltage

In the selection of transformer, since output voltage of the generator is the input voltage

of the transformer, the transmission voltage is the one that should be computed. According to

American practice, the economical transmission for three (3) phase AC system could be

determined by the formula:

Where, V = line voltage, kV

 P = maximum power per phase (in kW) to be delivered over single
circuit.
L = distance of transmission in km

Economical transmission voltage is the voltage for which the cost of conductors, cost of

insulators, transformers, and switchgear and other terminal apparatus is minimum. Since the

power that should be transmitted and the approximate length of transmission line is known based

on the given map. Using the equation:

MATERIAL AND EQUIPMENTS SPECIFICATION

STEP-UP TRANSFORMER
PRODUCT TYPE : POWER TRANSFORMER
VECTOR GROUP : DELTA-WYE (DYn)
PHASE :3
POWER RATING : 750 kVA
FREQUENCY : 60 HZ
PRIMARY VOLTAGE : 4160 VOLTS
PRIMARY MAX AMP CURRENT : 210 AMPS
SECONDARY VOLTAGE : 100,000 VOLTS
SECONDARY MAX AMP CURRENT : 8.4 AMPS
WINDING CONDUCTOR : COPPER
TEMPERATURE RISE : 150 deg. C
SOUND LEVEL : 70 dB
EFFICIENCY AT 35% LOAD : 99.24
ENCLOSURE TYPE : NEMA 3R
WEIGHT : 4,060 LBS
Step-down Transformer (Distribution Transformer)

Since the mini-hydroelectric power plant is intended purely for residential community, no

other consumers will need higher voltage other than 220-230 V so the transmission voltage is

brought down to 220-230V which is the standard voltage that is used for home appliances. A

post transformer is needed to make it possible which is also the step-down transformer.

Figure 1TYPICAL ELECTRICAL CONNECTION IN HYDROELECTRIC POWER PLANT

VI. CONCLUSION AND RECOMMENDATIONS

It can be concluded that with the computed data for flow rate = 2.74 m3/s, net head = 27.4

m, and penstock diameter = 1.1 m, with a total power output of 675 kW, the demand of

600 kW can be supplied, including the projected increase in demand for the next 10

years.

At present, the need for power supply keeps increasing, and this Mini Hydro Power Plant

Design can help future designers in developing power generation to help support the

community it will supply power with.

It can be therefore recommended that:

 There should be a back-up generator that can support the system in times of

emergency of the existing one and during repair and maintenance.

 The line voltage is determined in a way it reduce other assets like transformer,

conducting wires and switch gear. Though it can be in medium voltage (mv) since

it will cost higher diameter of conducting wires and will cost more power losses

that’s why it is designed in higher voltage.

 A capacitor bank should be included in the design so that dummy load is not

wasted by the electronic load controller which uses the power a ballast.

 A design consideration for a high turbine efficiency can be achieved by

considering hairline thickness between the turbine blade and spiral casing.

 The actual topography of the area and site location must be determined to allow

minimum bends in the penstock.