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DESIGN OF MICRO-HYDROPOWER SYSTEM FOR A STAND-
ALONE RURAL VILLAGE ELECTRIFICATION
ALPHONSUS SONG HUA BING
Bachelor of Engineering with Honours
(Mechanical and Manufacturing Engineering)
2010
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UNIVERSITI MALAYSIA SARAWAK
R13a
BORANG PENGESAHAN STATUS THESIS
Judul: DESIGN OF MICRO-HYDROPOWER SYSTEM FOR A STAND-ALONE RURAL VILLAGEELECTRIFICATION
SESI PENGAJIAN: 2009/2010
Saya ALPHONSUS SONG HUA BING
(HURUF BESAR)
Mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti
Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Membuat pendigitan untuk membangunkan Pangkalan Data kandungan Tempatan.4. Pusat khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan
tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
5. ** Sila tandakan ( √ ) di kota yang berkenaan
SULIT (Mengandungi maklumat uang berdarjah keselamatan atau kepentingan
Malaysia seperti uang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/
Badan di mana penyelidikan dijalankan).
TIDAK
TERHAD
Disahkan oleh
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap:
No.1C LANE 10 LADA ROAD Dr. ANDREW R.H RIGIT
Nama Penyelia
96000 SIBU SARAWAK
Tarikh: Tarikh:
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan
menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT dan TERHAD.
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APPROVAL SHEET
This project report which entitled “DESIGN OF MICRO-HYDROPOWER SYSTEM FOR A
STAND-ALONE RURAL VILLAGE ELECTRIFICATION” was prepared by Alphonsus Song
Hua Bing (15935) is hereby read and approved by:
Dr.Andrew R.H Rigit Date
Project Supervisor
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DESIGN OF MICRO-HYDROPOWER SYSTEM
FOR A STAND-ALONE RURAL VILLAGE
ELECTRIFICATION
ALPHONSUS SONG HUA BING
Thesis is submitted to
Faculty of Engineering, University Malaysia Sarawak
In Partial Fulfillment of the Requirements
For the Degree of Bachelor of Engineering
With Honours (Mechanical and Manufacturing Engineering) 2010
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To my beloved family and friends
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ACKNOWLEDGEMENT
I would like to express my appreciation to those who had given assistance and
help throughout this entire project. First of all, I would like to thanks my
supervisor, Dr. Andrew R.H Rigit for all the guidance and advices that had been
given in order to ensure the project can be complete in time. Secondly, thanks are
also given to author ’s friends and other members of Mechanical Engineering
Department, Unimas. Last but not least, special thanks to author’s parents for
financial support during studies in Unimas.
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ABSTRACT
Micro-hydropower system is a system that used to produce electricity. Its main
concept is transfer the kinetic energy of water flowing to electric energy by a
generator. When water flows from a head, the water flowing contains kinetic and
potential energy. Thus, when water flows knocked the turbine bucket, the turbine
will rotate and turning the generator. Generator can produce electric energy
through rotation of dynamo that will cut through electromagnetic field. These all
mechanisms are the main features of a complete micro hydropower system. The
main objective of this study is to identify the equations used to do calculation
regarding the system and main output is the parameter such as size of nozzle and
turbine that need to use to produce desired power output. A program is created
using Matlab7 software that includes the combination of equations to do
calculation on deciding size and parameter of components that will be used
during installation of the system. There are also a few limitations in this study
such as the flexibility of the equation used in program created, system efficiency
and limitation of materials selection for designing penstock system which the
thickness can be calculated in the program. Recommendations are given to make
the entire process more accurate and some problem can be solved.
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ABSTRAK
Sistem mini tenaga hydro merupakan satu sistem yang digunakan untuk menjana
tenaga elektrik. Konsep utama sistem ini adalah menukar tenaga kinetic aliran air
kepada tenaga elektrik dengan menggunakan generator. Apabila air mengalir dari
satu ketinggian, pengaliran air mengandungi tenaga kinetic dan tenaga yang
berpotensi. Oleh itu, semasa air mengalir memukul baldi turbine, turbine akan
berpusing dan memutar generator. Generator dapat menghasilkan tenaga elektrik
melalui putaran dynamo yang memotong medan electromagnet. Semua
mekanisme ini merupakan sifat-sifat utama sistem mini tenaga hydro yang
lengkap. Tujuan utama penyelidikan ini adalah mengenal pasti persamaan-
persamaan yang digunakan untuk membuat pengiraan tentang output utama
seperti saiz nozzle dan turbine yang digunakan untuk menjana tenaga elektrik
yang diperlukan. Dalam penyelidikan ini, beberapa had yang tidak dapat
diselesaikan juga akan dibincangkan. Satu program juga direka dengan
menggunakan perisian Matlab7.
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TABLE OF CONTENT
Page
ACKNOWLEDGEMENT ii
ABSTRACT iii
ABSTRAK iv
LIST OF TABLE viii
LIST OF FIGURE ix
CHAPTER 1 INTRODUCTION
1.1 Energy Market Tendencies 1
1.1.1 What is Mini-Hydro? 5
1.2 Background of Micro-Hydropower System 6
1.3 Problem statements 7
1.3.1 Is Micro-Hydropower for you? 8
1.4 Objective of the study 9
1.5 Summary 9
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 10
2.2 Micro-Hydropower definition and components 11
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2.3 How to Identify a Potential Site 13
2.4 Planning for a System 18
2.4.1 How to Measure Potential Power and Energy 18
2.5 Basic Components of a Micro-Hydropower System 25
2.5.1 Civil Works Components 252.5.2 Powerhouse Components 31
2.5.3 Transmission/Distribution Network 38
2.6 How to Choose a System 39
2.6.1 Case Study 1 39
CHAPTER 3 METHODOLOGY
3.1 Introduction 42
3.2 Method of identification problem 42
3.2.1 Methods of identification to measure water flow rate 43
3.2.1.1 Container Method 443.2.1.2 Float Method 45
3.2.1.3 Weir Method 45
3.2.1.4 Salt and Conductivity Meter Method 47
3.2.1.5 Current Meter Method 483.2.1.6 Summary 49
3.2.2 Method of identification to determine and measure head 49
3.2.2.1 Sighting Meters 493.2.2.2 Dumpy Levels and Theodolites 50
3.2.2.3 Water-Filled Tube and Rod Method 51
3.2.2.4 Altimeters 52
3.2.3 Method of identification of penstock system 52
3.2.3.1 Method of identification constraints in deciding 53diameter of penstock
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3.2.3.2 Method of identification constraints in deciding 54
wall thickness
3.2.4 Method of identification of turbine system 55
3.3 Conclusion 58
CHAPTER 4 RESULT AND DISCUSSION
4.1 Introduction 59
4.2 Equation analysis 60
4.2.1 Penstock analysis 60
4.2.2 Turbine analysis 654.2.2.1 Operation of Pelton turbine 66
4.2.3 Nozzle analysis 69
4.3 Operation of Program created using Matlab7 69
CHAPTER 5 CONCLUSION AND RECOMMENDATION
5.1 Colclusion 78
5.1.1 Colebrook-white equation (Haaland equation) 78
5.1.2 System efficiency 79
5.1.3 Thickness of penstock 80
5.2 Recommendation 80
REFERENCES 81
APPENDIX 83
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LIST OF TABLES
Table Page
1.0 Typical Power Output (in Watts) With Various Head and
Water Flow Rates 22
2.0 Comparison of Penstocks Materials 30
3.0 Typical Efficiency of Turbines and Water Wheels 36
4.0 Integrated Micro-Hydropower Systems 39
5.0 Approximate correction factor 45
6.0 Choosing a turbine depending to head available in site 55
7.0 Roughness value for different materials 61
8.0 Entrance loss coefficient for pipe 62
9.0 Head loss coefficient for bends 63
10.0 Head loss coefficients for valves 64
A List of Mini Hydro Power Stations in Malaysia 84
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LIST OF FIGURES
Figure Page
1.0 A waterwheel in action 12
2.0 Principal components of a micro-hydropower system 13
3.0 A typical micro-hydropower weir 14
4.0 A small stream suitable for a micro-hydropower system 17
5.0 Head of a micro-hydropower system 19
6.a Flow duration curve for river with a high flow 24
6.b Flow duration curve for river with more steady flow 24
7.0 An intake weir for a 7-kW system 26
8.0 Intake for a 2-kW micro-hydropower system 27
9.0 Wooden screen for a 24-kW micro-hydropower system 28
10.0 Powerhouse for an 8-kW system 31
11.0 A 20-cm (8-in) pitch diameter Pelton turbine runner 33
12.0 Pump-as-turbine with 12-kW output 33
13.0 Poncelet design of water wheel 34
14.0 Basic types of Water Wheels 35
15.0 A directly coupled Pelton turbine 38
16.0 A 200-W micro-hydropower system in action 41
17.0 Measuring water flow rate using container method 44
18.0 Measuring water flow rate using weir method 46
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19.0 Flow measurement using an integrating meter 48
20.0 Measuring head using Abney-level method 50
21.0 Solid Brass 5-inch Abney Level 50
22.0 Theodelite 51
23.0 Measuring head using spirit level and plank method 51
24.0 Altimeters 52
25.0 Schematic diagram of penstock system 53
26.0 Bending of penstock 63
27.0 Schematic diagram of Pelton turbine 67
28.0 Program created using Matlab7 70
29.0 Program with initial input 71
30.0 Relative roughness and Reynolds number 72
31.0 Nozzle diameter and ratio between runner diameterand runner revolution speed 73
32.0 The estimated thickness and minimum thickness 74
33.0 Efficiency of different parts of Hydro System 79
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CHAPTER 1
INTRODUCTION
1.1 Energy Market Tendencies
In Malaysia, the developing country, there are many industries mushrooming
around industrial areas from light industries to heavy industries. Examples of
these industries are automotives industries (heavy industries) such as PROTON
and PERODUA, LB Aluminum Berhad which main task is extruding aluminum
to sizes and shapes, and Oriental Food Industries Holdings Berhad (OFI) (light
industry) which activities are manufacturing and marketing snack food and
confectioneries. Industries mentioned above consume high electricity, and thus,
lead to key factor of high demand of electric supply in Malaysia. To ensure
continuous supply with least cost of electricity, few renewable energy supplying
methods are introduced in Malaysia such as hydropower generating electricity,
solar energy, biomass, wind energy, nuclear energy and etc.
Due to environmental concern and limitation of technologies, hydropower might
be the most cost effective way to generate electricity especially in Malaysia, a
high amount of annual rainfall country. In Malaysia, existing hydropower
examples are listed in Appendix A. According to Tenaga National Berhad, most
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of the hydropower stations located in rural areas which are geometrically suitable
for their continuous falling stream of water. From the table, there are a total of
5366.1MW of capacity of installation of hydroelectric dams in Peninsular
Malaysia, Sabah and Sarawak. This shows the importance of hydropower in
Malaysia as constant supplier of electricity.
According to Peter Fraenkel (1991), among all the renewable energies, the
hydropower occupies the first place in the world which is 86% of Global
electricity generation from renewable energy for large hydro power (over 10
MW) and it will keep this trend for many years to come. He also stated that the
market today for small and medium sized hydroelectric power plant is more
attractive than ever after due to some reasons below:
Hydropower dams disrupt the natural flow of rivers. This will alter
the river and riverside habitat. Arising high in the North Carolina
Appalachians, the Chattooga River travels a rugged 50 miles before
ending in Lake Tugalo’s still waters. For much of its journey, the
Chattooga forms the state line between South Carolina and Georgia.
On May 10, 1974, Congress designated the Chattooga be protected as a
National Wild and Scenic River. The protection was awarded because of
the river’s outstanding scenery and recreation, and its wildlife, geologic,
and cultural values. The river is famous with white water thrill seekers,
and is well known among trout anglers. Even though the Chattooga Rive
and Lake Tugalo are still mighty impressive, it did, never the less, alter
the ecology of that region.
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Impedes the natural flow of sediments. Rivers naturally erode, carry,
and deposit sediment. These processes are what shape the river, form
meanders, pools, and riffles. The river deposits its sediment load in the
impoundment when the flow velocity slows and the particles settle out.
Over time, sediment can fill in the impoundment.
Eventually, the impoundment may become so shallow that the sediment
must be removed by dredging or other means. The river downstream of
the dam is “starved” for sediment because the sediment naturally flowing
in the river has been trapped behind the dam. The water flowing through
the outlet of the dam may be relatively clear, and carry little sediment.
Scour holes. Water flowing over a dam can cause scour holes to form
immediately below the dam. Scour holes may undercut the foundation of
the dam threatening the integrity of the structure. In addition, the currents
in scour holes present a hazard to swimmers.
Obstacles to fish migration. Here is another of the disadvantages of
hydropower. According to the Water Resource Management practicum:
"Building a dam on a river has major implications for the biota found in
the river system. Because fish and other biota cannot move past a dam,
the dam effectively splits the river into separate ecological zones: the
river above the dam and the river below the dam.
Fish passages may be added to a dam to help fish move up and
downstream, but they are not always effective. Although the free
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movement of fish can sustain a healthy fishery, a dam may be a barrier to
the movement of unwanted invasive species.
Water tends to warm more in an impoundment than in a free-flowing
river, which may affect the types of fish found upstream, in, and
downstream of the impoundment. Impounded and free-flowing river
systems provide habitat for amphibians, reptiles, birds and mammals.
Catastrophic Failure. If dam breaks it would be a disaster and would
kill many people. One classic example in American history is the
Johnstown Flood. According to Wikipedia: "The Johnstown Flood
disaster (or Great Flood of 1889 as it became known locally) occurred on
May 31, 1889. It was the result of the failure of the South Fork Dam
situated 14 miles (23 km) upstream of the town of Johnstown,
Pennsylvania, USA, made worse by several days of extremely heavy
rainfall. The dam's failure unleashed a torrent of 20 million tons of water
(18.1 million cubic meters/ 4.8 billion gallons). The flood killed over
2,200 people and produced US$17 million of damage."
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1.1.1 What is mini hydro?
Small hydro is the development of hydroelectric power on a scale serving a
small community or industrial plant. The definition of a small hydro project
varies but a generating capacity of up to 10 megawatts (MW) is generally
accepted as the upper limit of what can be termed small hydro. This may be
stretched to 25 MW and 30 MW in Canada and the USA.
In contrast many hydroelectric projects are of enormous size, such as the
generating plant at the Hoover Dam (2,074 megawatts) or the vast multiple
projects of the Tennessee Valley Authority. Small hydro can be further
subdivided into mini hydro, usually defined as less than 1,000 kW, and micro
hydro which is less than 100 kW. Micro-hydro is usually the application of
hydroelectric power sized for small communities, single families or small
enterprise.
Small hydro plants may be connected to conventional electrical distribution
networks as a source of low-cost renewable energy. Alternatively, small hydro
projects may be built in isolated areas that would be uneconomic to serve from a
network, or in areas where there is no national electrical distribution network.
Since small hydro projects usually have minimal reservoirs and civil construction
work, they are seen as having a relatively low environmental impact compared to
large hydro.
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1.2 Background of Micro-Hydropower System
Hydro power plants convert potential energy of water into electricity. It is a clean
source of energy .The water after generating electrical power is available for
irrigation and other purposes. The first use of moving water to produce electricity
was a waterwheel on the Fox River in Wisconsin in 1882. Hydropower continued
to play a major role in the expansion of electrical service early in this century
around the world. Hydroelectric power plants generate from few kW to
thousands of MW. They are classified as micro hydro power plants for the
generating capacity less than 100 KW. Hydroelectric power plants are much
more reliable and efficient as a renewable and clean source than the fossil fuel
power plants. This resulted in upgrading of small to medium sized hydroelectric
generating stations wherever there was an adequate supply of moving water and
a need for electricity. As electricity demand soared in the middle of this century
and the efficiency of coal and oil fueled power plants increased, small hydro
plants fell out of favor. Mega projects of hydro power plants were developed.
The majority of these power plants involved large dams, which flooded big areas
of land to provide water storage and therefore a constant supply of electricity. In
recent years, the environmental impacts of such large hydro projects are being
identified as a cause for concern. It is becoming increasingly difficult for
developers to build new dams because of opposition from environmentalists and
people living on the land to be flooded. Therefore the need has arisen to go for
the small scale hydro electric power plants in the range of mini and micro hydro
power plants. There are no micro hydro power plants in Malaysia and the
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smallest category of hydro power plants in Malaysia is mini hydro with a
capacity between 500 kW to 100 kW.
1.3 Problem statements
Micro Hydro is a popular resource across the globe. Since it is renewable and
does not harm the environment, many homes and companies are beginning to
look into installing turbines into their own local streams. Micro Hydro is a very
site-specific resource. Without the proper head or flow, the system does not
function properly. Sites need at least a 1m head, and the water must be moving to
activate the turbine. Areas that are flat or have stagnant water must install costly
canals to move the water. Micro Hydro is already very popular in the United
Kingdom and Europe. The system is beginning to spread to Australia and rural
parts of North America. Soon Micro Hydro could show in areas closer to the east
coast of the USA.
Micro Hydro is beginning to develop in Asia and Africa and
around the rest of the world also. For rural areas, which cannot be included in
normal power grids, this provides a small amount of electricity that can make a
large impact on those it reaches. Less than 1 kW of power is more than sufficient
to power an entire house in most situations. People who have never experienced
the benefits of modern technology can be reached through this power and begin
to improve their lives.
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1.3.1 Is Micro-Hydropower for you? (BC Hydro. Handbook for Developing
Micro Hydro in British Columbia (Draft), 2002)
You may have wondered whether the stream flowing through or near your
property can be used to generate electrical power using a hydropower system to
power your home. Is a micro-hydropower system feasible for you? Many factors
will determine the viability of such a system:
Local, provincial/territorial and federal legal restrictions on the
development of the hydroelectric site and the use of the water
The amount of power available from the stream and its ability to meet
energy and power requirements
The availability of turbines and generators of the type or capacity
required
The cost of developing the site and operating the system
1.4 Objective of the study
To conduct the site-study, stream-mapping, and assessment for the
Technical Feasibility stage at the chosen sites.
To design the appropriate layout for a micro-hydropower system that is
proportional according to the selected site.
Identify the equations used to do calculation.
Software is also developed using MATLAB7 to calculate the relative
roughness of penstock, Reynolds number, diameter of nozzle for the
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micro hydro power plants, ratio between runner diameter and runner
revolution speed, once the capacity is known.
1.5 Summary
As Micro Hydro power continues to grow around the world, it is important to
show the public how feasible Micro Hydro systems actually are in a suitable site.
Micro-Hydropower system is the most cost effective way and environmental
friendly method to bring just sufficient electricity for a Stand-Alone Rural
Village Electrification.
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CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This literature review is based on development and basic component of a Micro-
Hydropower system which include planning of a system, how to choose a system
regarding the economics factors and brief discussion about installing, operating
and maintaining a system. From this literature review also it will basically stated
the past experiment or work that had been done by the Hydraulic Energy
Program, Renewable Energy Technology Program, CANMET Energy
Technology Centre (CETC) in cooperation with the Renewable and Electrical
Energy Division (REED), Electricity Resources Branch, Natural Resources
Canada (NRCan). Review and input from NRCan’s Office of Energy Efficiency,
Energy Systems & Design Inc., Homestead Hydro Systems, Morehead Valley
Hydro Inc., Thompson and Howe Energy Systems Inc., Josée Bonhomme,
Robert Clark, Scott Davis and Stephen Graham.