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
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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 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
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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 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
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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 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
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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."
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.
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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.
