Professional Documents
Culture Documents
3 Micro-
Micro-Hydro
4.3.1 Designing
Tokyo Electric Power Co. (TEPCO)
Contents
1-Nov-05 (12:01)
1
Civil Structure: Weir
1-Nov-05 (12:01)
Types of Weir
¾ Concrete gravity dam
¾ Floating concrete dam
¾ Earth dam
¾ Rockfill dam
¾ Wet masonry dam
¾ Gabion dam
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Characteristic of Weir
1-Nov-05 (12:01)
Cut-off
Longer epron
2
Characteristic of Weir
1-Nov-05 (12:01)
Characteristic of Weir
1-Nov-05 (12:01)
Concrete reinforced gabion dam Bush wood dam Wooden frame with gravel dam
3
Concerns to be addressed in Weir Designing
1-Nov-05 (12:01)
¾ Location of weir site
9 Perpendicular to river direction
9 Topographical & geological conditions
9 Easy access
¾ Structural Stability
9 Fall resistance, Sliding resistance & Soil bearing capacity against resultant
external force (weir own weight, water pressure, sedimentation weight, earth
quake & up lift)
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¾ Sedimentation
9 Easy flushing
9 Existing landslide, debris, erosion, drift woods etc.
¾ Backwater effect
9 Influence on upstream area during flooding
Type of Intake
¾ Side intake
9 Typical intake
9 Perpendicular to river direction
¾ Tyrolean intake
9 Along the weir Side Intake
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9 Simple structure
9 Affected by sedimentation
during flooding
9 More maintenance required
Tyrolean Intake
8
4
Civil Structure: Settling Basin
1-Nov-05 (12:01) Function
9 All the suspended materials that could
adversary affect turbine should be removed.
Dam
Intake Spillway
Specification to be decided Stoplog Flushing gate
2.0
Conduit section
9 Length & wide Widening section
Settling section
Bsp
10 ~15 cm
hsp+15cm
Stoplog
Intake
hi h0
hs
ic=1/20~1/30
Sediment Pit
Flushing gate
Lc Lw Ls
bi L
Function
9 Conveys water from intake to forebay
Specification to be decided
9 Structure type (Open channel)
9 Longitudinal slope (1/50 – 1/500)
9 Cross section (flow capacity)
9 Material to be used
Qd=A×R2/3×SL1/2 /n
where,
Qd: Flow capacity (design discharge: m3/s )
A: Cross-sectional area
R: R = A/P
P: Length of wet sides
P
A
SL: Longitudinal slope
n: Coefficient of roughness
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5
Characteristic of Headrace
1-Nov-05 (12:01)
Simple earth Lined channel Wet masonry Concrete channel
Type
channel (Rock & stone) channel
9 Easy construction 9 Easy construction 9 Local material 9 Great flexibility of
9 Inexpensive 9 Local material 9 Scouring resistance cross section
Advantage 9 Easy repair 9 Scouring resistance 9 Applicable to design
9 Easy repair permeable ground
9 Easy construction
9 Risk of scouring & 9 Not applicable to 9 Relatively expensive 9 Not applicable to
collapse high permeable 9 More man power small diameter
9 Not applicable to ground 9 Long construction
Disadvantage high permeable period
ground
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9 Difficult to remove
sedimentation
Characteristic of Headrace
1-Nov-05 (12:01)
Type Wood fenced channel Box culvert channel Hume pipe channel
9 Inexpensive 9 Easy construction 9 Easy construction
9 Flexible to minor ground 9 Short construction period 9 Short construction period
Advantage deformation 9 Applicable to small diameter 9 High resistance to external
9 Flexible to cross section pressure
figure 9 Applicable to small diameter
9 Not applicable to big 9 Heavy weight 9 Heavy weight
Disadvantage diameter 9 High transportation cost 9 High transportation cost
9 Easy to decay
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Wooded-fenced channel Box culvert channel Closed pipe (Hume pipe, steel pipe)
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6
Civil Structure: Forebay
1-Nov-05 (12:01)
Function
9 Regulates discharge fluctuation Screen
difference between penstock &
headrace due to load fluctuation.
9 Final settling basin
Spillway
Specification to be decided
9 Water storage capacity
9 Layout & dimension of each facility
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Headrace
Headrace Penstock
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Function
9 Convey water under pressure from
forebay to turbine
Specification to be decided
9 Route (Slope, geological conditions
etc)
9 Material to be used
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9 Diameter
- Construction cost
- Electricity generation decrease due
to loss at penstock
- Durability (Life time, O&M cost)
9 Thickness
- Water pressure, own weight, water
weight, other external force (earth
quake etc.)
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7
Powerhouse
1-Nov-05 (12:01) Powerhouse
z Function:
Provides shelter for the electro-mechanical equipment (turbine,
generator, control panels, etc.)
z Foundation:
Classified into two:
•For Impulse turbine
-Pelton turbine, Turgo turbine or cross-flow turbine, etc.
•For Reaction turbine
-Francis turbine or propeller turbine, etc.
15
The figures shows the foundation for the cross flow turbine. There
is a space between center level of the runner and the tailwater level
A
1 .1 × Q d 2 1/ 3
hc ={ 9 .8 × b2
}
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hc
H L3
A
(atmosphere pressure) A fterb a y T ailrac e c anne l O utle t
S ection A -A
bo
b o : d ep end s o n Q d and H e
20cm 2 0 cm
b
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8
Foundation for Reaction Turbine
1-Nov-05 (12:01)
b. Foundation for Reaction Turbine
The below figures show the foundation for the Francis turbine. The
outlet level of the draft tube is under the level of tailwater
A
d3
ThisHs:head is also
depens on characteristic effectively utilized
of turbine
2
1.1×Qd 1/ 3
hc={ 9.8× b2
}
Hs
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20cm
hc
Filled with water 1.15 × d3
Section A-A
1.5×d3
17
Effective Head
1-Nov-05 (12:01)
HL1
Settling Basin
Forebay HL2
Penstock
H Hg
Powerhouse He
HL3
Tailrace
18
9
Calculation of Head Loss
1-Nov-05 (12:01) The head loss at the penstock (HL2) can be calculated by
the following equations.
HL2 = hf + he + hv + ho
where,
hf: Frictional loss at penstock
he: Inlet loss
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19
hf = f ×(Lp/Dp ) ×Vp2/2g
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10
<Reference > Head Loss at Penstock
1-Nov-05 (12:01) (2) Inlet Loss
hi = fe × Vp2/2g
(4) Others
Bend loss and loss due to changes in cross-sectional area are considered
other losses. However, these losses can be neglected in micro-hydro
schemes. Usually, the person planning the micro-hydro scheme must take
account of following margins as other losses.
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11
Design of E/M Equipment
1-Nov-05 (12:01)
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1. Inlet Valve
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2. Water Turbine
Types:
z Impulse turbines: Rotates the runner by the impulse of water jets
by converting the pressure head into the velocity head through
nozzles.
z Reaction turbines: Rotates the runner by the pressure head.
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Type Head
High Medium Low
Impulse Pelton Crossflow Crossflow
Turgo Turgo
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12
Design of E/M Equipment
1-Nov-05 (12:01) Pelton Turbine
¾Acting water jet emitted from the nozzle to the bucket of runner
¾Good characteristics for discharge change
- Discharge: Small (0.2 – 3 m3/s)
- Head: High head (75 – 400m)
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25
Pelton Turbine
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13
Design of E/M Equipment
1-Nov-05 (12:01)
Cross-Flow Turbine
¾Arc shape runner blades are welded on the both side of iron plate discs
¾Easy manufacturing and simple structure
- Discharge: Small (0.1 – 10 m3/s)
- Head: Low, middle head (2 – 200 m)
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Water
Cross-
Cross-Flow W/T
Guide Vane
27
Cross-Flow Turbine
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14
Design of E/M Equipment
1-Nov-05 (12:01)
Francis Turbine
¾Wide ranging utilization from various head and output
¾Simple structure
- Discharge: Various (0.4 – 20 m3/s)
- Head: Low to high (15 – 300 m)
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Francis Turbine
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15
Design of E/M Equipment
1-Nov-05 (12:01)
Reverse Pump Turbine (Pump as Turbine)
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Tubular Turbine
¾Tubular type(Cylinder type) propeller turbine
¾Package type is remarked recently
- Discharge: Various (1.5 – 40 m3/s)
- Head: low head (3 – 20m)
Draft Tube
16
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Pico Hydro
Tubular Turbine
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17
Design of E/M Equipment
1-Nov-05 (12:01)
Flow chart of designing hydro turbine
Power plant H,Q Range of Ns
Turbine type
(m-kW)
Number of units Pelton 8 – 25
Francis 50 – 350
Turbine type selection by
Diagonal flow 100 – 350
the selection chart
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35
(328)
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10
Cross Flow
(32.8)
Horizontal Francis
(3.28)
1 Horizontal Propeller
0.01
(0.3529) 0.1
(3.529) 1
(35.29) 10
(352.9) 100
(3,529)
3 3
Water Discharge (m /s, ft /s)
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18
Design of E/M Equipment
1-Nov-05 (12:01) 3. Generator
z Synchronous:
Independent exciter rotor, applicable for both isolated and existing
power networks
z Asynchronous (induction):
No exciter rotor is usually applicable in networks with other power
sources. In isolated networks, it must be connected to capacitors to
generate electricity.
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Where
Pg: Capacity (kVA)
H : Net head (m)
Q: Rated discharge (m3/s)
η: Combined efficiency of turbine & generator etc (%)
pf: Power factor ( %)
37
3. Generator
Speed and Number of Generator Poles
- The rated rotational speed is specified according to the frequency
(50 or 60 Hz) of the power network and the number of poles by
the following formula:
19
Design of E/M Equipment
1-Nov-05 (12:01)
Standard rated speeds and number of poles for synchronous
generators
No. of poles 50 Hz 60 Hz
4 1500 1800
6 1000 1200
8 750 900
10 600 720
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12 500 600
14 429 514
16 375 450
18 333 400
20 300 360
24 250 300
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Parallel-in
Structure Operation
operation
• Excitation • Voltage • Synchronizer
circuit regulation • Less electro-
Synchronous • Relatively large • Reactive power mechanical
generators air gap adjustment impact at parallel-
(Usually lagging in
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power factor)
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20
Design of E/M Equipment
1-Nov-05 (12:01) 4. Driving Facility (Speed Increaser)
To match the speed of the turbine and generator
– Gearbox type:
The turbine shaft and generator shaft are coupled with gears
with parallel shafts in one box with anti-friction bearings
according to the speed ratio between the turbine and generator.
The life is long but the cost is relatively high. (Efficiency: 95 –
97%, depending on the type)
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– Belt type:
The turbine shaft and generator shaft are coupled with pulleys
or flywheels and belts according to the speed ratio between the
turbine and generator. The cost is relatively low but the life is
short. (Efficiency: 95 – 98%, depending on the type of belt)
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21
Design of E/M Equipment
1-Nov-05 (12:01) (2) Dummy load type: Customers of Electricity
Transformer
Generator output is always
constant at a micro hydro
Upper Dam
power station where a
dummy load governor is
applied to. In order to keep
the frequency constant, the
relationship “generator
output = customers load +
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Spillway
dummy load” is essential. Upper Reservoir
The dummy load is controlled
Power House
by an electronic load
controller (ELC) to meet the Dummy Load Governor
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22
Design of E/M Equipment
1-Nov-05 (12:01) 5.2 Generator Exciter
In the case of a synchronous generator, an exciter is
necessary for supplying field current to the generator
and keeps the terminal voltage constant even though
the load fluctuates. The type of exciter is classified as
follows:
• DC exciter:
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• AC exciter:
The excitation circuit
consists of an AC PT
exciter directly AVR
Pulse
Generator
CT
coupled to the main (Speed Detector)
Ex. Tr
generator, a rotary
rectifier and a
separately provided
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maintenance cost)
Brushless exciter
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23
Design of E/M Equipment
1-Nov-05 (12:01)
• Static excitation:
Direct thyristor
excitation method. PT
Pulse
DC current for the AVR Generator
CT
field coil is supplied (Speed Detector)
through a slip ring Ex. Tr
from a thyristor
with an excitation
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transformer. (Low
Slip ring
initial cost but high
maintenance cost)
G
Static excitation
47
6. Switchgears
Single Line Diagram:
The typical single diagram for a 380/220V distribution line
Magnet
Contactor NFB Fuse
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A x3 To Custmer
x3
Lamp
V Indicator
Hz V
x3
Turbine
H
ELC
G (with Hz Relay) Dummy Load
Transmitter Generator
if required
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24
Design of E/M Equipment
1-Nov-05 (12:01)
Switchgear board including ELC
CB(MCCB)
ELC
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NFB
49
7. Control Panels
50
25
Design of E/M Equipment
1-Nov-05 (12:01)
7.2 Instrumentation
51
Considering the same reason for cost saving in instrumentation, the following
minimal protection is required for micro-hydro power plants in rural
electrification.
1. Over-speed of turbine and generator (detected by frequency)
2. Under-voltage
3. Over-voltage
4. Over-current by NFB (No Fuse Breaker) or MCCB (Molded Case Circuit
Breaker) for low-tension circuits.
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Design of E/M Equipment
1-Nov-05 (12:01) Exercise
There is a potential site with the following conditions:
Net head: 10 m
Discharge: 1 m3/s
Frequency: 50 Hz
Synchronous generator is required.
Q3: How wide of the rotational speed range will be applicable for
the selected turbine when the turbine efficiency is 0.6?
53
Answer
There is a potential site with the following conditions:
Net head: 10 (m)
Discharge: 1 (m3/s)
Frequency: 50 (Hz)
Synchronous generator is required.
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Design of E/M Equipment
1-Nov-05 (12:01)
Selection of turbine type
1000
(3,280)
(m, ft)
Horizontal Pelton
Vertical Francis
100
Effective Head
(328)
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Cross Flow
10
(32.8)
Horizontal Francis
(3.28)
1 Horizontal Propeller
0.01
(0.3529) 0.1
(3.529) 1
(35.29) 10
(352.9) 100
(3,529)
3 3
Water Discharge (m /s, ft /s)
55
Answer
Q3: How wide of the rotational speed range will be applicable for
the selected turbine when the turbine efficiency is 0.6?
A3: The turbine output P is
P = 9.8 ηt Q H = 9.8 × 0.6 × 1 × 10 = 58.8 (kW)
so that the minimum and maximum rotational speeds are
calculated as follows:
Nmin = Nsmin × H5/4 / P1/2
= 200 × 105/4 / 58.81/2
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= 463 (min-1)
Nmax = 900 × 105/4 / 58.81/2
= 2087 (min-1)
Considering the standard rated speed, the speed range from
500 to 1500 (min-1) is applicable for the direct coupled
generator.
In case that 500 (min-1) is selected as the turbine rated speed
considering turbine characteristics, a speed increaser is
preferable to apply because lower speed generators are costly.
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