STUDY ON MICRO HYDRO POWER PLANT AS A SITE LABORATORY IN

UNIVERSITI TEKNOLOGI MALAYSIA

MOHD SHAFIQ BIN ANUAR

A project report submitted in partial fulfilment of the

requirements for the award of a degree of

Master of Engineering (Electrical-Power)

Faculty of Electrical Engineering

Universiti Teknologi Malaysia

JUNE 2012

iii

Special for:

My beloved wife

Madihah Md Rasid

My soon to be born child

My father and my mother …

Anuar Sulaiman

&

Ruhani Ab. Rahman

My father and mother in law

Md Rasid Suib

&

Kalsom Raduan

also to my brothers and sisters…

In thankful appreciation for support and encouragement to

my supervisor…

Dr. Yanuar Z. Arief

iv

ACKNOWLEDGEMENT

Alhamdulillah, finally I manage to complete my project which is a pre-requisite

for my Master of Engineering (Electrical - Power). I am so blessed to Allah who gave

me tremendous courage, strength and spirit while facing all the obstacles all this while.

There is nothing more important except giving a special thanks to my supervisor

Dr. Yanuar Z. Arief for all his advice, stimulating suggestions, concerns and supports

during the research, from the beginning till the end of this thesis.

Furthermore, I would like to express my special gratitude to my wife, Madihah

Md Rasid for his valuable advice and friendly help. Her extensive discussions

throughout my work and the interesting explorations have been very helpful for this

study.

Thanks also to my colleague, Mohd Fahmi Abdul Rahim who have been

involved directly or indirectly during the completion of this project. His help and ideas

are much appreciated.

For my last dedication, my sincere thankful is also extends to my father, mother

and siblings for their never ending support and understanding throughout my master

study.

v

ABSTRACT

As the price of fossil fuels is increasing daily, the need for cheaper electricity

generation rises. The most efficient and environmental friendly is generated from mega

hydro power plant. However, due to large area needed, a smaller hydro plant is more

suitable. A prototype of a smaller scale hydro plant known as Micro Hydro Power Plant

(MHPP) is trying to be built in this project. This project is initiated since there is no

available prototype to be used as site laboratory in Universiti Teknologi Malaysia

(UTM). This project will be the catalyst for further research regarding the MHPP. It

also supports the fifth fuel policy introduced by Malaysia in 8th and 9th

Malaysia plan.

Firstly, this project identifies the feasibility of site in UTM. Site visits and data

gathering are done at all seven locations. Then, gathered data are calculated based on

the formula found during literature review. The results show which site is the most

suitable based on the output power calculated. The site with the highest output power is

chosen as the trial site. Design stage begins once the site has been chosen; design is

suited with the requirements of the chosen site. Six items are considered in the design

stage. A prototype is then being built based on the design that has improves the

reference model obtained during literature review stage. Experiments are done at the

early construction stage to know the functionality of the prototype. Once the prototype

is ready, trials are done to measure its performance. During trials, prototype constructed

is capable of generating electricity. Objectives of the project are achieved and this

project is a success.

vi

ABSTRAK

Dengan kenaikan harga bahan api fossil setiap hari, keperluan untuk menjana elektrik

dari sumber yang lebih murah menjadi semakin tinggi. Loji janakuasa berasaskan air

adalah paling cekap dan mesra alam. Namun begitu, disebabkan cara ini memerlukan

tanah yang amat luas bagi membina empangan. Disebabkan ini, pembinaan loji

janakuasa berasaskan air berskala kecil adalah lebih sesuai. Prototaip loji janakuasa

kecil akan dibina didalam projek ini. Projek ini diilhamkan kerana tiadanya prototaip

yang dapat digunakan sebagai makmal sementara di Universiti Teknologi Malaysia

(UTM). Projek ini diharapkan akan menjadi pemangkin kepada penyelidikan pada masa

hadapan. Projek ini turut menyokong polisi minyak kelima yang diperkenalkan oleh

Malaysia di dalam Rancangan Malaysia ke 8 dan ke 9. Projek ini akan mengenalpasti

tapak yang sesuai di dalam UTM. Lawatan tapak dan pengumpulan data akan

dijalankan di kesemua tujuh lokasi. Pengiraan berdasarkan formula dan data yang

diperolehi akan dilakukan. Keputusan dari pengiraan akan menunjukkan kesesuaian

lokasi. Lokasi yang mempunyai kuasa keluaran yang tertinggi dipilih sebagai tapak

percubaan. Fasa reka bentuk akan bermula setelah tapak percubaan dipilih, reka bentuk

akan mempertimbangkan keperluan di tapak percubaan. Enam perkara direka di fasa

ini. Prototaip akan dibina berdasarkan model rujukan yang telah diperbaiki. Eksperimen

dijalankan semasa pembinaan untuk mengetahui tahap keberjayaan fasa pembinaan.

Setelah prorotaip siap dibina, percubaan di tapak yang telah dipilih akan dilakukan bagi

mengenal pasti kuasa keluarannya. Percubaan menunjukkan prototaip yang dibina

mampu menjana elektrik. Semua objektif projek dicapai dan projek ini dianggap

sebagai berjaya.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION Ii

DEDICATION Iii

ACKNOWLEDGEMENT Iv

ABSTRACT V

ABSTRAK Vi

TABLE OF CONTENTS Vii

LIST OF TABLES Xi

LIST OF FIGURES Xiii

LIST OF ABBREVIATIONS Xv

LIST OF SYMBOLS Xvi

LIST OF APPENDICES Xvii

1 INTRODUCTION

1.0 Introduction 1

1.1 Background of Study 2

1.2 Problem Statements 3

1.3 Objectives 4

1.4 Scope of Project 5

1.5 Thesis Organization 5

viii

2 LITERATURE REVIEW

2.0 Introduction 7

2.1 Classification 8

2.2 Sites 9

2.3 Important Formulas 10

2.3.1 Output Power Formula 10

2.3.2 Gear Ratio Formula 12

2.4 Design Stage 13

2.4.1 The Waterwheel 14

2.4.2 The Gear Ratio 14

2.4.3 The Water Channel/ Penstock 15

2.4.4 The Alternator 16

2.4.5 The Support Structure Material 16

2.4.6 The MHPP Configuration 16

2.5 Conclusion 17

3 METHODOLOGY

3.0 Introduction 18

3.1 Literature Review 19

3.2 Site Visit and Data Gathering 19

3.2.1 Current Meter 20

3.2.2 Precise Level 22

3.2.3 1.136L Bottle and Stopwatch 22

3.3 Designing The MHPP Prototype 23

3.3.1 The Waterwheel 23

3.3.2 The Gear Ratio 25

3.3.3 The Water Channel/ Penstock 26

3.3.4 The Alternator 28

3.3.5 The Support Structure Material 29

3.3.6 The MHPP Configuration 30

ix

3.4 Construction and Trial of Prototype 31

3.5 Conclusion 32

4 RESULTS AND DISCUSSIONS

4.0 Introduction 34

4.1 Equipments 35

4.2 Data Measurements 35

4.2.1 Using Current Meter 35

4.2.2 Using 1.136L Bottle 36

4.2.3 Using Precise Level 37

4.3 Theoretical Results 38

4.3.1 Theoretical Results 1; Using Current Meter and

Precise Level

39

4.3.2 Theoretical Results 2; Using 1.136L Bottle and

Precise Level

40

4.3.3 Conclusion 41

4.4 Design Results 41

4.4.1 Conclusion 42

4.5 Experimental Results 42

4.6 Trial Results 44

4.6.1 Trial Results 1 45

4.6.2 Trial Results 2 47

4.6.3 Trial Results 3 49

4.6.4 Trial Results 4 51

4.6.5 Conclusion 53

4.7 Discussion 53

4.7.1 Results Discussion 53

4.7.2 Reasons for Trial Results Not Achieving the

Design Results

55

4.7.2.1 Low RPM Value 55

4.7.2.2 Low Flow Rate 56

x

4.7.2.3 Lower Head Value 58

4.8 Conclusion 58

5 CONCLUSIONS AND RECOMMENDATIONS

5.0 Introduction 60

5.1 Overall Conclusion 60

5.2 Recommendations for Future Works 62

REFERENCES 63

Appendices A-J 66-75

xi

LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 Classification of Hydro Power Plant

8

3.1 Available Gear Ratio

25

4.1 Velocity of Water Using Current Meter

36

4.2 Flow Rate of Water Using Current Meter

36

4.3 Average Time of Water to Fill Up 1.136L Bottle 37

4.4 Flow Rate of Water Using 1.136L Bottle

37

4.5 Head Measurement Using Precise Level

38

4.6 Theoretical Results 1

39

4.7 Theoretical Results 2

40

4.8 Design Results

41

4.9 Experimental Results

41

xii

4.10 Trial Results 1

45

4.11 Trial Results 2

47

4.12 Trial Results 3

49

4.13 Trial Results 4

51

4.14 Trial Results in Percentage Compared to Design Results 54

xiii

LIST OF FIGURES

FIGURE NO. TITLE PAGE

2.1 50% Efficiency Value Calculation 11

2.2 Reference Model 13

2.3 Pitchback Waterwheel (90% Efficiency) 14

2.4 Pipe Channel and Overshoot Waterwheel 15

3.1 Waterwheel for MHPP Prototype 24

3.2 Gear ratio a) Waterwheel (T1=42), b) Alternator (T2=13) 26

3.3 Configuration of Water Channel for Site G 27

3.4 Alternator 28

3.5 Alternator Configuration 28

3.6 Inside Alternator 28

3.7 The Support Structure for The Waterwheel 30

3.8 MHPP Configuration at Site G 31

3.9 Each Trial Differences at the Blade Design 32

4.1 Graphical View of Theoretical Results 1 39

4.2 Graphical View of Theoretical Results 2 40

4.3 Experimental Results a) Voltage b) Current c) Power 43

4.4 Trial Results 1 a) Voltage b) Current c) Power 45

4.5 Trial Results 2 a) Voltage b) Current c) Power 47

4.6 Trial Results 3 a) Voltage b) Current c) Power 49

4.7 Trial Results 4 a) Voltage b) Current c) Power 51

4.8 Design Results and Trial Results 54

xiv

4.9 RPM Values for Each Trial, Before and After Battery

Connection

56

4.10 The Water Diversion Angle 57

4.11 Head Values for Theoretical, Design and Trial 58

xv

LIST OF ABBREVIATIONS

UTM - Universiti Teknologi Malaysia

MHPP - Mini Hydro Power Plant

TNB - Tenaga Nasional Berhad

JUPEM - Jabatan Ukur dan Pemetaan Malaysia

UMP - Universiti Malaysia Pahang

FKE - Fakulti Kejuruteraan Elektrik

FRP - Fiberglass Reinforced Plastics

FKA - Fakulti Kejuruteraan Awam

FKSG - Fakulti Kejuruteraan Sains Gunaan

RPM - Rounds Per Minute

xvi

LIST OF SYMBOLS

P - Power

P - Rho

g - Gravity

𝑄 - Water Flow Rate

ℎ - Head

o - Efficiency

𝑒 - Efficiency

m - Mili

𝜋 - Pi

μ - Mikro

% - Percentage

𝑆 - Speed

T - Number of Teeth

k - Kilo

A - Ampere

V - Volt

M - Mega

W - Watt

xvii

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Seven Locations of Site Visits 66

B Precise Level 67

C Current Meter 68

D 1.136L Bottle 69

E Digital Multimeter 70

F Digital Tachometer Shimpo 71

G Current Meter Data and Results 72

H 1.136L Bottle Data and Results 73

I Measurement Data Using Precise Level 74

J Data and Design Results 75

CHAPTER 1

INTRODUCTION

1.0 Introduction

19% of the world‟s electricity power is contributed from the hydropower,

making it the most widely used of renewable energy [1, 2]. This includes power

generated from both large and small power plants. In addition to that, hydropower

contributed around 6% of total world energy demand [3]. In Malaysia, the electricity

generation that utilizes the hydropower started in July 1900 with the construction of a

small hydroelectric plant by the Raub-Australian gold mining company at the bank of

Sempam River near Raub, Pahang [4, 5]. According to [4], electricity was only

commercially available around 1970s to be supplied to domestic use. Nevertheless,

Malaysia have come a long way to generate more electricity, to date, there are twelve

large scale hydropower plant and fifty mini scale hydropower stations in progress.

Bakun project which one of the large scale project that is still in progress can generate

electricity up to 2 400 MW. In 2009, 18 500 MW of Malaysia‟s electricity demand is

generated from hydropower and this number represents 20% of Tenaga Nasional Berhad

(TNB) generating capacity [6, 7].

2

Hydropower converts energy which available in falling water into electricity.

The basic principle of hydropower is that by channeling the water from higher to lower

level, the resulting potential energy can be used to do work. The water head is then used

to move a mechanical shaft, which converts potential energy to mechanical energy.

From here, the turbine is now moving and electricity is generated. This shows that

hydropower is a clean source of energy and only uses water because no fuel is needed to

be burnt and this means there are no effects to the environment when generating the

electricity [3].

Eventhough hydropower is a clean source of energy when generating the

electricity, there are other effect towards the environment resulting from the construction

of the hydro power plant. The most significant effect towards the environment is due to

the construction of the dam to provide water storage that will need to flood a large area.

This step is crucial to make sure that a constant supply of electricity is possible. The

plant is usually constructed in the rural which is the habitat of flora and fauna and

flooding it means that their habitat will be destroyed. This raises a new problem to

developers to build new dams because of opposition from the environmentalists and

people living in the flooded area [3]. Due to this, the need for a smaller hydropower

plant rises.

1.1 Background of Study

With the rising need for a smaller hydropower plant, the construction of Micro

Hydro Power Plant (MHPP) is vital to cater the rising electricity demand. According to

[8, 9, 10, 14], MHPP is categorized as plant that can generate power in the range of 5

kW to 100 kW. The construction of MHPP will also be beneficial to the people who are

in the rural since the plant only needed a small area. With the construction of MHPP, the

electricity can be made available to the rural and can help improve their lifestyle.

3

By observation, in Universiti Teknologi Malaysia (UTM) there are not less than

seven locations that are suitable for the construction of MHPP. The resources such as

water and land are readily available. With a few adjustment and enhancement, the

available locations may be the best location to construct the MHPP.

The study is done to get the best design to generate the highest possible output

based on the available resources in each location. Based on earlier study done by [12]

and [13], the geographic of UTM which is hilly in nature is suitable for the MHPP site.

In addition to that, according to the Metrological Department of Malaysia, the rainfall in

Skudai is averaging at 250 mm. [9] has also done the research based on the data from the

Metrological Department of Malaysia and Jabatan Ukur dan Pemetaan Malaysia

(JUPEM) and based on their research, twelve sites are available for the construction of

MHPP with the total estimated available power of 1,687.9 kW.

1.2 Problem Statement

According to research done, there are no MHPP to be used as site laboratory in

Malaysia. However, according to [17], Universiti Malaysia Pahang (UMP) has done

research to develop a pico hydro prototype. However, it was not for site laboratory

usage. It is to be used as domestic and commercialized loads. This serves as proves that

there are no site laboratory for MHPP is available in Malaysia as of now.

To help students to understand how the electricity generation works, this project

is proposed. It is also hope that more research regarding the small hydro power plant

will be done. This study will be a pioneer and a catalyst towards the future research and

study in MHPP.

4

The current situation for UTM students is that they need to travel all the way to

Kelantan or Terengganu to do site visit at a hydro power plant. This is a waste of money

and time since the distance between UTM and these places are more than 500

kilometers. Not to mention that the equipments are expensive and very sensitive. It also

generates power to for millions of Malaysians in real life. It means that during the visits,

no changes can be made since it may affect the consumers; they can only look and see.

With the construction of the prototype of MHPP as a site laboratory, since the load can

be varied accordingly, the generation can also be varied this means that students and

researchers can understand more with the changes being made at the generation and the

load site. Another advantage of having the site laboratory is that it can be a pioneer so

that improvements can be made in the design so that a more efficient, cost saving and

environmentally friendly green energy source can be achieved.

In addition to that, “Fifth Fuel Policy” introduced by the Malaysian government

in the eighth and ninth Malaysia Plan also includes hydro as one of the fuel towards

generating energy [11]. With the Malaysia Plan as the backbone, by successfully

constructing the prototype, it is believed that more research towards the small hydro

power plant will be done.

1.3 Objectives

There are several objectives of this project which are:

1) To study and analyze the feasibility of sites in UTM to be the MHPP

2) To design the MHPP prototype based on the data gathered and calculation done

3) To construct a prototype of MHPP as site laboratory in UTM for educational

purposes

5

As mentioned in the third objective, the prototype is for educational purposes

only. Thus, the output of the prototype is not a big concern. However, the design stage

will try to design the prototype so that the output can be in the required range of the

MHPP classification that is between 5 kW to 100 kW.

1.4 Scope of project

To achieve the said objectives, this project will study and review previous papers

and research to get the relevant formula and conclusive view of the MHPP. Once the

formula has been identified, site visits will be done to gather the required data. The data

gathering will be done using verified techniques to make sure that the data gathered are

reliable. Once the required data are available, the calculations are done to get the

probable output of each location. From the output calculated, the design will be

constructed and to get the highest output possible, design improvements will be made

based on the reference model. The last part is to construct the MHPP prototype and do

trial at sites. The trial is very important to verify the calculation and to make sure that

the prototype is well functional.

1.5 Thesis Organization

This thesis will be discussing in detail the design stages, the data gathered and the

probable output based on the calculations done. This thesis will be divided into five

chapters. Chapter one; Introduction, Chapter Two; Literature Review, Chapter Three;

Methodology, Chapter Four; Results and Discussion and Chapter Five; Conclusion and

Recommendations.

6

Chapter one; Introduction will be discussing the background of the study,

objectives and scopes of study. Chapter two will discuss in detail the reviewed papers

regarding the design of the MHPP and comparisons will be made to get the most suitable

design to generate the highest output. This chapter will also identify the main formula of

this project. The methodology chapter will be discussing the methods used in this project

in order to get the final stage of constructing the MHPP prototype and doing the trial at

sites.

Chapter four will then discuss the results obtained. Chapter four will also be

discussing the reasons if there are differences between the design and the trial results.

While in chapter five, conclusion and recommendations for future works are discussed.

REFERENCES

[1] J.K.Kaldellis, „The Contribution of Small Hydro Powerstations to the Electricity

Generation in Greece: Technical and Economic Considerations’, Energy Policy

Journal, Volume 35, pg 2187-2196, 2007, Uhttp://www.elsevier.com/locate/enpolU

[2] Yilmaz Azlan, Oguz Arslan, Celal Yasar, „A Sensitivity Analysis for the

Design of Small Scale Hydropower Plant, Kayabogazi Case Study’, Renewable

Energy Article, April 2007, Uhttp://www.elseview.com/locate/reneneU

[3] Uhttp://www.microhydropower.netU

[4] The Asean Association for the Promotion of Cogeneration (COGEN ASEAN),

Background Report, „Overview Instruments for the Promotion of Renewable

Energy and Energy Efficiency in Malaysia’, 2004.

[5] Thahirah Syed Talal, Pat Bodger, „The Development of Electricity Supply

Industry in Malaysia‟, Universiti Tenaga Nasional (Uniten) Graduate Student

Conference on Research and Development, 2008.

[6] Pusat Tenaga Negara (PTM), „National Energy Balance Report’, Malaysia,2001.

[7] Tenaga Nasional Berhad (TNB), „TNB Annual Report 2008’, 2008.

[8] Mohibullah, Mohd. Amran Mohd. Radzi, Mohd Iqbal Abdul Hakim, „Basic

Design Aspects of Micro Hydro Power Plant and Its Potential Development in

Malaysia’, IEEE, 2004.

64

[9] Nathan Raman, Ibrahim Hussein, Kumaran Palanisamy, ‘Micro Hydro Potential

in West Malaysia’, IEEE, 2009.

[10] Minister of National Resource Canada, ‘Small Hydro Project Analysis

Chapter’,2004.

[11] Malaysia National Energy Policies, Uhttp://eib.ptm.org.my/indexU

[12] Mohd Mustaqeem Mohd Hassan, „Micro Hydro Power System at Faculty of

Electrical Engineering, UTM (Part 1)’, 2005, UTM.

[13] Mohd Nafis Ismail, ‘Micro Hydro Power System at Faculty of Electrical

Engineering, UTM (Part 2)’, 2005, UTM

[14] The Intermediate Technology Development Group (ITDG), „Micro-Hydro

Power’, 1998 Uhttp://www.practicalaction.org/U

[15] Uhttp://www.whitemill.org/z0028.htmlU

[16] Uhttp://en.wikipedia.org/wiki/Micro_hydro#Turbine_typesU

[17] Ahmed M.A. Haidar, Mohd F.M Senan, Abdulhakim Noman, Taha Radman

„Utilization of pico hydro generation in domestic and commercial loads’,

Renewable and Sustainable Energy Reviews 16 (2012) 518– 524

[18] Gear Ration Calculations, available at,

Uhttp://www.schsm.org/html/gear_ratio_calculations.htmlU

[19] Azhar Khairuddin, ‘Power Generation’, lecture notes for MEP1633 2010/2011-1

65

[20] Sembang Pasal Sprocket Rantai, available at,

Uhttp://125zmalaysia.forumms.net/t31p15-sembang-pasal-sprocket-rantaiU

[21] Penstock, available at,

Uhttp://en.wikipedia.org/wiki/PenstockU

[22] Introduction to Micro Hydro, available at

Uhttp://www.google.com.my/url?sa=t&rct=j&q=&esrc=s&source=web&cd=17&v

ed=0CHUQFjAGOAo&url=http%3A%2F%2Fmcedc.colorado.edu%2Fsites%2F

default%2Ffiles%2FMicro-

Hydro%2520(2).pdf&ei=iSLcT8bBLc3QrQep2cyxDQ&usg=AFQjCNEQk316m

H4e_hzAZaXc890qDRHK1w&sig2=CflQvZgKJ30rdH6ZbaeklQU