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

UNIVERSITI MALAYSIA SARAWAK

R13a

BORANG PENGESAHAN STATUS THESIS

Judul: DESIGN OF MICRO-HYDROPOWER SYSTEM FOR A STAND-ALONE RURAL VILLAGE

ELECTRIFICATION

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.

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

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

i

To my beloved family and friends

ii

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.

iii

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.

iv

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.

v

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

vi

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 25

2.5.2 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 44

3.2.1.2 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 48

3.2.1.6 Summary 49

3.2.2 Method of identification to determine and measure head 49

3.2.2.1 Sighting Meters 49

3.2.2.2 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 53

diameter of penstock

vii

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 65

4.2.2.1 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

viii

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

ix

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

x

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 diameter

and runner revolution speed 73

32.0 The estimated thickness and minimum thickness 74

33.0 Efficiency of different parts of Hydro System 79

1

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

2

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.

3

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

4

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."

5

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.

6

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

7

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.

8

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

9

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.

10

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.