College of Engineering

Department of Mechanical Engineering

Spring 2017-18
Senior Design Project Report
Windmill Water Pump
Design of Windmill for Pumping Water
In partial fulfillment of the requirements for the
Degree of Bachelor of Science in Mechanical Engineering
Team Members

Student Name Student ID

1 Hussain Alhijji 201303810

2 Yassin Alsalman 201400301

3 Mohammed Taher 201403887

4 Yousef Albrahim 201301938

5 Abdulhadi Brrqaan 201303926

Project Advisors:
Advisor Name: Aymen Jendoubi
Co-Advisor Name: Raguraman Kannan

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Abstract

The demand of alternative sources of energy in increasing significantly due to the

increasing cost of the traditional energy sources. Wind energy is one example of alternative
sources of energy that will be designed for the purposes of pumping water. There are two
types of windmill turbines Vertical axis windmill turbine and horizontal axis windmill
turbine. This project will only consider the horizontal axis wind turbine. The design of
windmill is very wide subject and therefore the design is based on data analysis of various
components of wind mill and their actual drawings. This include the rotor assembly i.e. the
blade on the hup, transmission shafts (both vertical and horizontal) which houses the gears,
actuating pulley and the piston actuating mechanism, tail and turntable. The design does
not cover the design and selection of the pump but the desirable pump that can function
with the vertical movement of the actuating rod will be selected. In order to achieve the
optimum design characteristics such as torque and power produced by the windmill,
various calculation and structural analysis had to be done as well.

Keywords: Wind, Turbine, Energy, Horizontal Axis, Pump.

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Acknowledgements

We would like to acknowledge and express our thanks to the people who provided
us with the insights and resources that helped make this project possible and to those who
helped us by taking time out of their busy schedules so that we could complete this
research. Among those who we would like to acknowledge is Dr. Aymen Jendoubi. We
would like to thank Dr.Aymen for all of the invaluable help and advice that he provided
during the course of this project. Without Dr. Aymen Jendoubi, this project would surely
have been much more difficult to conduct.

Also among those who we would like to acknowledge is Dr. Muhammad Asad. We
would like to thank Dr. Asad for his constructive criticism and helpful ideas, all of which
made this project run more smoothly. Dr, Panos Sphicas is last but not least among the
individuals who we would like to thank. Dr. Panos was kind enough to take time out of his
busy schedule to help us as we completed this project. Finally, we would like to thank the
Department of Mechanical Engineering at Mohammad Bin Fahd University. [1]

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Table of Contents

ABSTRACT ................................................................................................................................................ 2

ACKNOWLEDGEMENTS .................................................................................................................... 3

1 Chapter 1: Introduction……………………………………………………………9

2 CHAPTER 2: LITERATURE REVIEW ................................................................................... 11

3 CHAPTER 3: SYSTEM DESIGN ............................................................................................... 24

BASE .................................................................................................................................................................. 36
3.4.2 Tower……………………………………………………………………………………………….……….38
3.4.3 Bearing …………………………………………………………………………………………………….39
3.4.4 Blade ……………………………………………………………………………………………………….40
3.4.5 Generator …………………………………………………………………………………………………41
3.4.6 Charge Controller ……………………………………………………………………………………...43
3.4.7 Battery …………………………………………………………………………………………………….44
3.4.8 Voltmeter …………………………………………………………………………………..…………….45
3.4.9 Anemometer ……………………………………………………………………………………..……..45
3.4.10 Tachometer ……………………………………………………………………………………………47
3.4.11 Water Pump ………………………………………………………………..…………………………49
3.4.12 Water Tank …………………………………………………………………………………………….51

4 CHAPTER 4: SYSTEM TESTING AND ANALYSIS ........................................................... 52

4.1.2 EXPERIMENTAL WIND TURBINE POWER CALCULATION ……………………….…54

GOALS ........................................................................................................................................................... 56
EXPERIMENTAL METHODOLOGY .......................................................................................................... 56

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 PROCEDURE................................................................................................................................................. 57

5 CHAPTER 5: PROJECT MANAGEMENT............................................................................. 58

5.4.1 Material and Equipment resourcing ……………………………………………………..…….64

5.4.2 DESIGN PROBLEMS .................................................................................................................................... 65
5.4.3 REPORT WRITING AND DOCUMENT ...................................................................................................... 66

6 CHAPTER 6: PROJECT ANALYSIS............................................................................................... 69

IMPROVE OUR SKILLS IN SOME SOFTWARE TOOLS ........................................................................ 69

TIME MANAGEMENT SKILL ................................................................................................................... 69
PROBLEM SOLVING................................................................................................................................... 70

6.2.1 Social…………………………………………………………………………………………………………70
6.2.2 Environment……………………………………………………………………………………………...70
6.2.3 Economy …………………………………………………………………………………………………..70
6.3 Contemporary Issues Addressed…………………………………………………………………...71

7 CHAPTER 7: CONCLUSION ........................................................................................................... 72

8 REFERENCES .................................................................................................................................... 75

9 APPENDIX A: CAD DRAWINGS ................................................................................................... 80

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 List of Acronyms (Symbols) used in the report:
[2] Cp - Coefficient of power
As - Swept Area
AB- Area of one blade
V - Velocity
Uo - Speed of Wind
- Density
D - Diameter
R - Radius
- Tip Speed Ratio
N - Number of Blades
- Angular Velocity
Ct - Torque Coefficient
݉݉ - Mass Flux
Pw - Wind Power
PT - Power Extracted From wind
T - Torque
g - Acceleration due to gravity
Q - Flow rate
H - Head
Ph - Hydraulic Power
Pd - Diametral Pitch
m - Module
- Gear Pressure angle
E - Young’s Modulus
- Poisson’s Ratio
y - Yield Strength
UTS - Ultimate Tensile Strength
- Shear Stress
J - Polar Moment of Inertia
F - Force
M - Moment

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 LIST OF FIGURES
FIGURE 1: WIND SPEED IN DAMMAM [2] ………………...…………….………....20
FIGURE 2: WIND SPEED IN HAIL [2] …………………………...……….…….…....21
FIGURE 3: WIND SPEED IN JIZAN [2] …………………………...……….................21
FIGURE 4: WIND SPEED IN MECCA [2] ……………………..…….……….….…....22
FIGURE 5: WIND SPEED IN MADINAH [2] …………………………………....…....22
FIGURE 6: WIND SPEED IN RIYADH [2] ……………………………………….......23
FIGURE 7: WIND SPEED IN TABUK [2] ……………………………….………........23
FIGURE 8: HAWT OVERVIEW LAYOUT [3] …………...……………………...…...29
FIGURE 9: BASE DESIGN [3] ………………………………….……………………..37
FIGURE 10: TOWER …………………………………………………..………………38
FIGURE 11: BARING DESIGN [3].............................……………..……….………….39
FIGURE 12: INDIVIDUAL BLADE [3] ……………………………………………….41
FIGURE 13: FIVE BLADE ASSEMBLY [3] …………………………………….........41
FIGURE 14: GENERATOR [3] ………………………………………………………...42
FIGURE 15: CHARGER CONTROLLER [3] …………………………………………43
FIGURE 16: BATTERY [3] ………………………….………………………………...44
FIGURE 17: VOLTMETER [3] …………………………….……………………….....45
FIGURE 18: ANEMOMETER [3] …………………………………………….……….47
FIGURE 19: TACHOMETER [3] …………………………………………………...…49
FIGURE 20: WATER PUMP [3] ……………………………………….……………...50
FIGURE 21: WATER TANK [3] ……………………………………………..….…….51
FIGURE 22: THEROTICAL POWER CALCULATION [4] ………………….….…..53
FIGURE 23: EXPERIMENTAL POWER CALCULATION [4] ……………………...54
FIGURE 24: THEORETICAL VS EXPERIMENTAL [4] …………………….………56

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 LIST OF TABLES:

TABLE 1: AVERAGE WIND SPEED IN DIFFERENT AREAS IN THE KINGDOM

[1]………………………………………………………………………..……….15
TABLE 2: WIND CHARACTERISTICS IN VARIOUS SITES [2] ……..……19
TABLE 3: CONTAINS DETAILS ON THE USED PARTS [3] ……....….…...24
TABLE 4: TIP SPEED RATION VS NUMBER OF BLADES [3].………..…..36
TABLE 5: BEARING STANDARDS [3] ………………………………….….40
TABLE 6: WATTS VS WIND SPEED [3] …………………….……………....42
TABLE 7: BATTERY SPECIFICATION [3] ………………….…………..…. 44
TABLE 8: WATER PUMP SPECIFICATIONS [3] ………..….………………50
TABLE 9 : THEORETICAL GAIN POWER CALCULATION [4]….…….....53
TABLE 10: EXPERIMENTAL GAIN POWER CALCULATION [4]….…....54
TABLE 11: THEORETICAL VS EXPERIMENTAL DATA [4] ……………..55
TABLE 12: DURATION OF THE TASKS [5]………………………….…..…60
TABLE 13: TASKS DISTRIBUTION [5] ………………………………....….63
TABLE 14: TABLE OF ACTIVITIES [5] ……………………………….……63
TABLE 15: LIST OF MATERIAL AND THEIR COST [5]………………..... 67

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 1 Chapter 1: Introduction

Project definition

Power generation is a major requirement nowadays, Saudi Arabia in specific is

looking for new methods to find renewable energy sources as part of 2030’s vision and
wind power was found to be suitable for the country’s geographic condition.

Wind is the motion of air that is moving on the surface of the earth, and its speed
varies based on the geographical location. The wind energy can be generated from the
change of atmosphere unevenly where some parts get warmer than others. The warmer air
rises and the colder air patches blow to replace them, therefore, alternating air is resulted
and that air is wind [1]. Windmill is a mill that is used to convert kinetic energy of the wind
into a mechanical energy by using blades rotor assembly which drives the shaft. The result
from the rotating shaft provides a mechanical work that can be used to pump water as an
example.

This project is intended to design a windmill based on the various components and
their actual drawings. This design will contain the rotor assembly i.e. blades, hub,
transmission shaft, the gear box, tower, generator, and yow system. Windmill has two
different designs, the first type is horizontal and the second type is vertical. In this project,
it will focus on the horizontal type. The consumption of power in Saudi Arabia is about
triple times the world average [2]. There comes the benefit of windmill as it will reflect
positively on the country in an economical point of view, as vision 2030 tries to find an
alternative power source other than petroleum. Using renewable energy sources will not
only benefit Saudi Arabia economically, but also will help the country to reduce its
pollution by using free green energy such as wind. The main advantage of windmill
compared with solar panel is that the country is located in a desert area where dust is very
common, the dust has a big impact on the solar panels. Moreover, solar energy only works
during the day while, windmill can operate 24 hours depending on the wind changes [4]

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 Objectives

The main objective of this project is to determine the power from a renewable
energy source which is the wind. Moreover, to design a windmill with the key
characteristics of a windmill. Another objective of this project is to practice and apply the
engineering concepts. But there are more objectives, which are:

1. Design and construct a windmill to produce a renewable energy which is going to

decrease the pollution.
2. Reduce the cost and energy of pumping water.
3. Study the difference between horizontal axis wind turbine, and the vertical axis
turbine.
4. Learn the advantages and disadvantages of windmill.
5. Identify mathematical equations.
6. Compare between theoretical and experimental power.

Project specifications

There are many necessary components that are the building blocks of a horizontal
axis wind turbine, these components starting from the pump, generator, shaft, bearing, rotor
and blades will be either designed or selected in accordance with engineering standards.
Further discussion of the components will be in section 3.1
.

Applications

The windmills that can be used in different applications to ensure they give the best
possible results. These applications maybe pumping water in large amounts such as in
farms, stand-alone system for homes and businesses, system for community centers,
schools and health clinics and also in industrial applications.

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 2 Chapter 2: Literature Review

This section explains the project’s background in terms of historical development, the
site selection which is a basic requirement for efficiency, the types of windmills developed
and the differences between each to give a better understanding. In addition, the advantages
and disadvantages are going to be illustrated to preview the main strengths and weaknesses
of the project. Also, an important discussion of previous work done on windmills is
included in this part followed by comparative studies as an ending to this part.

Project Background

For its lower cost production and eco-friendliness, wind energy has been developed
over the years as a major alternative source of energy. Though pinpointing the very
beginning of wind as a power source is unknown, it has been recorded that its first usage
was as an aerodynamic lift for sailboats around 3500 BC in Ancient Egypt. Adapting this
advanced invention, the wind wheel, windmill, and wind turbine were gradually brought
to life as seen throughout world history. The timeline is going to be skipped in this segment
until the invention of horizontal axis type of windmill which followed after the Persians
introduced the vertical design in 200 BC to grind grains.

1300 AD – Western Europe adopted the first use of horizontal axis windmill due to
its larger efficiency compared to the vertical type. This design of windmill was mainly for
irrigation, prioritizing it over its secondary function of grinding grains, as the water in
France would come from Netherlands. Moreover, the naming “Windmill” was indicative
of respect, power, wealth, and high authority. The villagers’ personalization of the
windmills was equivalent to village hierarchy. Meanwhile, due to the fact that friction mills
are made of wood, they were highly combustible. High winds also made a miller’s job
dangerous as wind gust can damage the mill arms; hence, to furl the sails the miller must
be very skilled and physically strong.

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 1270 AD – The Post design version of horizontal axis type of windmill was
invented, wooden, upright and massive, the entire windmill rotated where the wind blew.
Its Vitruvian characteristic was adapted from a horizontal axis water wheel transmitting
the rotary motion of the blades to a grindstone which was also horizontally structured and
ring gears and wooden cogs were used.

12th Century – The Post mill was used in Arles, France.

13th Century – It was of utmost significance for irrigation with a route via Holland,
Germany to France and England, aside from the waterwheel.

1390, 14th-15th Century – The Tower design version of horizontal axis type of
windmill was built. Several stories of an elevated tower were mounted with a Post
windmill. Bricks were used but the roofing was made of woods. The first floor housed the
miller and his family while the revolving top was for blade-positioning, contrary to the Post
design. A large wheeled lever at the back and lateral fan were eventually added. Then again,
storms made the miller look after the mill at all times. Thus, it was also known as “runaway
mill.”

16th Century – The octagonal Dutch Smock mill came into existence highlighting
a turn-able top. Lighter woods were used for its body as it was more convenient for the
damp quagmire. Besides grinding grains, the smock design was for Dutch polders requiring
drainage.

17th Century – In Europe, the slow windmill with eight blades were designed.
Unlike a runaway turbine’s destructive tendencies, the wind gust used was moderate with
each of the mill’s blade spinning around in its own axis. With the use of a tie rod and a
crankshaft, it self-regulated into driving a single-action water pump.

18th – 19th Century – The Dutch Smock mill was standardized in Europe.

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 1870 – While the eight-bladed design was not popular in Europe, it spread
throughout America due to its triumphant, economic and simple design. It became the
American windmill, a.k.a. the Western mill, when it went back to Europe and became
worldwide later on.

Mid-1870’s – The fantail, a wind-driven sail located opposite the main sails, was
devised.

Mid-19th Century – The Western mill was mainly used for providing drinking
water and water for steam locomotives. It was distinctive of its more than 20 blade sheets
with a 3 to 5 m diameter, referred to as rotor rosette.

1890 – The first experiments for generating electricity using the Western mill
began.

1891 – An automatic four-bladed electric-producing wind turbine was developed

by Paul LaCour in Denmark. To be able to use it in far-flung areas, a DC generator was
built along with it. It was produced for more than fifty years and played a major role during
World War I.

1920 – The actuator disc theory application became relevant in wind turbines
converting 59 percent of the kinetic wind energy to mechanical energy.

1941-1945 – The first grid-connected Megawatt wind turbine was designed and
developed by Palmer Putnam together with Smith, a water turbine firm in USA.

1957-1962 – In Denmark, the Gedser wind turbine came into existence. Leading
the Sjaelandic electricity supplier’s grid expansion division, Johannes Juul built it as robust
but simple. Its simple aerodynamic rotor separated the burly winds’ flow; thereby, limiting
power passively but fully. In times a grid fails, the edges of the blades flapped as breaks.

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 1958-1968 – The prototype W34 with two blades made of fiberglass was
conceptualized. Producing 50Hz AC power, it had a pitch control that is electro-hydraulic.

21st Century – Global wind power capacity has been steadily increasing. The
world’s largest wind power market has been transferred back and forth by US, China, and,
Germany.

Site Selection

One of the most important aspects of how efficient the wind turbine would be is the
location of the windmill. The wind speed of any location is not constant; hence, the location
of the windmill has to have sufficient wind power as well as away from any obstacles to
avoid any turbulence. Also, analysis of the wind energy of a certain location must be
recorded for a period of at least one year to determine whether the location is suitable to
install the windmill or not. Most windmills are located in hilly areas or making sure that
the tower is high enough to insure it is a way from any obstacles [12]

The following charts are obtained from a previous project that includes the average
mean wind speed in various areas around the kingdom.

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 Table 1: average wind speed in different areas in the kingdom

Annual mean wind speed at different heights at Rawdat Ben Habbas.

Types of Wind Turbines

There are two types of windmills; Vertical and Horizontal axis wind turbine, each
has its own upsides and downsides of the variations between the two.

2.3.1 Vertical axis wind turbine (VAWT):

A wind turbine secures the air into a hub which then moves in rotations and the air
passes through the blades gets spun into a generator by rotational momentum. The vertical
axis wind turbine is designed to be economical and very practical. This type of turbines is
always used in residential areas the vertical axis wind turbine is usually shorter in terms of
height than the horizontal axis wind turbine. In addition, there are two main different style
designs of vertical axis wind turbine. The first design is Darrieus wind turbine, and the
second is Savonius wind turbine. The most common used is the Savonius model. Most of
the vertical axis wind turbines’ features the following qualities.

2.3.2 Horizontal axis wind turbine (HAWT):

Wind industry nowadays is primarily dominated by the Horizontal Axis Wind

Turbine. As the name suggests, Horizontal axis wind turbine means that the axis of rotation

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of the wind turbine is horizontal. The major advantage of the HAWT is its ability to use as
much wind as possible to produce more energy at all times, where the downside of the
HAWT is that the efficiency decreases when the winds are turbulent. [7]

Advantages and Disadvantages of Wind Power

Power generation is the most critical problem of today’s constantly developing

world. Thus, early planning is very important to secure every requirement and avoid every
possible mistake and before doing that, evaluation of the advantages and disadvantages of
wind power to decide how much planning is needed.

Wind power is considered the go to solution for future energy shortages. It is now
perceived as one of 2030 plans to preserve or create energy. Each idea has its advantages
and disadvantages which both shall be evaluated to determine what has more power over
the other. So, when it comes to wind power, its advantages are that it is considered a type
of renewable energy; meaning that it depends on natural resources to generate power, it is
also cost effective; the amounts and efforts spent on fulfilling a wind power project would
get a positive pay at the end so there shall be no\ minimum waste. In addition, it is
considered environment friendly as it does not produce gases or require any harmful
substances to operate and once it is not harming the environment, it saves costs of plans
and reaches to preserve the environment. Moreover, it is a sustainable source of energy,
whenever there is wind; there would be energy, it does not have to be searched for nor it
would require gases. From another aspect, benefits of a wind power are that it can be added
to even already built locations so it does not require new locations to implement it and also,
form another aspect, having wind power is supposed to secure jobs on the long term. [3]

As from the challenges aspect, there are challenges that wind power projects may
come across which are: the fact that the geographic location is going to affect the efficiency
of wind power as the locations that are known for a windy climate would generate more
power than areas that have mostly dry climate during the year in addition to how exposed
to lightning strokes the area is. There is also the challenge of the difficult development of

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wind power as throughout many years, not a lot of technical development was reached
regarding wind power where is still operates on the basic and same mechanics without
managing the few back draws it may have. [4].

On the other hand, there are few disadvantages of wind power such as the blades,
as they may damage the bird’s life in the surrounding area or such as the noise from the
turbines that are used to convert the wind power to an electrical one, they may create a
loud noise when many are operated at the same time, so yes it is possible to install it in
already built locations but the locations would have to be chosen in locations far from
living areas. And there is the disadvantage of land consuming, where the locations as
mentioned, has to be set far from living areas. Moreover, manufacturing and maintenance
are costly, so a budget must be sat regularly to insure these two. [8]

Previous Work

The Aeroleaf Wind Turbine was a project that got its name from its design idea
where it focused on making it suitable to be used in parks and open areas. The project
utilized Savonius turbines to operate even though it is not considered a familiar thing due
to its low wind-speed start up, its operation with any wind direction and its minimal noise
in comparison to other turbines. It converts wind power through its speed to rational
motions and it is able to generate power that reaches 300 watts. The project focused on the
design as a main strength point, then the fabrication and finally the evaluation process.
Also, the project helped come with a VAWT framework to increase the power yield.
However, the main difference between the project of subject and Aeroleaf is the fact that
the project of subject’s turbine is designed on a horizontal access while the other is
designed on a vertical access [10].

2.6 Comparative Study

Following are comparative studies explained to illustrate the various uses of wind
power in locations that are different from Saudi Arabia in many ways.

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2.6.1 Study of Wind Water Pumping System in Tunisia

As the Preparatory Institute for Engineering Studies of SFAX has mentioned, the
wind through the renewable energy plays an important role for the water supply. This study
has shown the perspective of the wind’s mechanical pumping in eight different sites
distributed at the Tunisian South. This study focuses at the energy evaluation of the wind
turbine SEN 5000 P8. From the geographic perspective, Tunisia is an arid country, where
regarding characteristics of sites selected, in this study, they were interested in the south
side of the country, which represents the good underground water resources. In additional
to that, south country diversity of the wind potential distribution. Indeed, the annual mean
wind speed (respectively available energy) varies between 2.7 and 3.5 m/s in South-east
(respectively 302 and 645 kWh/m2 /year) and varies between 4.6 and 5 m/s in Southwest
(respectively 1150 and 1997 kWh/m2 /year) [5].

2.6.1.1 Table 2: Wind characteristics in various sites

This table shows how the wind characteristic in various sites in Tunisia. As
discussed above, the south side of the country has more wind velocity which generates
more electricity compared with the other sites based on the wind speed and geographical
location. In this study, there will be a comparison between different sites to see where will
be the most critical location to use the windmill at, then there will be a comparison between
Saudi locations to show different locations with different wind speed.

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 Table 2: wind characteristics in various sites

2.6.2 Wind power utilization for water pumping using small wind turbines in
Saudi Arabia

In king Fahd University, there was a study which was taken in Arar, Rawdat Ben
Habbas and Juaymah localities in Saudi Arabia to utilize power of the wind for pumping
water for remotely located inhabitants not connected with national power grid. The study
was based on data which was collected for years from different heights which are 10, 20,
30, and 40m. The study used the known data for wind speed, and calculates the amount of
pumped water at different heights. The study proved that higher wind speeds were noticed
during summer time compared to winter time at all the locations and is showed that annual
total water pumping capacity of 30,000 m3 is possible from a depth of total dynamic head
of 50 m when using 2.5 kw and also proved that wind turbine with hub heights of 15–40
m at all three sites had cost of water pumping as low as 1.28 USb/m3. [11]

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 Wind Speed in Saudi Arabia

As Saudi Arabia being majorly desert, the winds powers differ from other
countries and actually from one area to another as some areas are higher. For a windmill
to function efficiently, the location with higher wind speed and power in general is better
to be selected. The following figures describe the change of wind power and percentages
around the year in multiple areas. (Dammam, Hail, Jizan, Mecca, Madinah, Riyadh and
Tabuk).

Figure 1: wind Speed in Dammam

ure

[22]

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Figure 2: wind Speed in Hail

[23]

Figure 3: Wind Speed in Jizan

[24]

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 Figure 4: Wind speed in Mecca

[25]
Figure 5: Wind Speed in Madinah

[26]

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Figure 6: wind Speed in Riyadh

[27]
Figure 7: wind Speed in Tabuk

[28]

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 3 Chapter 3: System Design

Design Constraints and Methodology

The constraints of the used parts are listed in table 3 the table will contain details
on the item, its size, the environment constraints effecting the part, the weight of the part
and its cost.

Table 3: Contains details on the used parts

Item Size Environment Weight Cost

Blades Five blades each Blades are made of carbon Each blades Cost of
blade is 0.7 m in fiber that will resist the weighs each blade
length and 0.15 m ultraviolet light about 0.450 is 71.25 SR
width. kg

Rotor – 28 magnet dual rotor To keep the windmill 3 kg Cost is 446

Alternator with 2 rectifiers and running in case of no or little SR
provides up to 2800 wind
watts output

17 mm shaft Coefficient of friction has to 1.5 kg 150 SR

be low and high tensile
Shaft strength must be present to
prevent dynamic load

Battery Standard 12 V battery Outdoor 12 volt. 25 kg

300 SR

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 Tower – 0.7 m in height Steel manufactured and 7 kg
Base coated for minimizing
corrosion 100 SR

Hub Hub thickness is 0.47 Zinc plated for corrosion Weighs Cost is 67
cm. Hub OD is 16.5 resistance about 0.7 kg SR
cm.

Hub Spacer 17 mm center with Gold zinc plated so it can 0.5 kg Cost of
and dimensions of (17.46 resist corrosion and won’t material is
stabilizer * 50.8 mm) rust 41 SR

Mounting 22 mm in height and Steel manufactured with hot 0.7 kg Cost is 190
Bracket 100 mm in length. galvanic dipping for SR
corrosion resistance

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Collar The inside diameters Made from high quality steel 1 kg Cost is 36
is 49 mm and the with high tensile strength. SR
outer diameter is 76 Zinc plated for corrosion
mm resistance.

Pump 12 Volts Internal mounted in tank 12 0.9 kg Cost is 250

volt dc, 1.6 gallon/ min SR

Constraints

A horizontal axis wind turbine can be used all over the world as long as sufficient
wind energy is present. However, there are many constraints that can affect the design of
the wind turbine such as:

1. Environment.
2. Economical
3. Manufacturability.
4. Safety.
5. Sustainability.
6. Engineering standards.

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3.2.1 Environmental Constraints

One of the most important factors or constraints to consider when approaching any
research is the environmental factors, as the environment can play a major role in
determining the efficiency of the project.

Wind turbines are a clean source of energy that can produce a considerable amount
of energy whenever a sufficient wind is present, thus, location of the wind turbine is crucial
as if no wind exists the turbine will not work. Also, because the prototype of this device is
relatively small compared to an actual wind turbine that usually produce loud sound when
operated, the sound produced can be very loud and it is advised that the wind turbine should
be installed at an area away from the general public to avoid this noise pollution.

3.2.2 Economical Constraints

There have been few obstacles faced in terms of economics. One of them was to
collect an amount to set the basic budget for buying the required materials, which for
students with no income, took a long time to reach the needed budget, also in the supplying
places where there were no student’s discount policies for the materials which were
required in addition to the cost of online transactions and shipping fees for the materials
ordered online. Oher than that, financing the workshops where the manufacturing process
was held was an issue, as the charge was calculated based on the time to finish, the personal
effort of the labor and the machines used.

3.2.3 Safety Constraints

Safety is an essential factor that must not be ignored or understated at any cost.
Wind turbines are safe to operate and use as they don’t produce emission, hence, there is
less or no chance of releasing toxic or hazardous material. A safe distance should be kept
from the device to avoid any hazard that the blade can cause when running on high speeds.
Noise is another factor to be considered, as an actual wind turbine produces loud noises

27 | P a g e
that can be harmful to individuals but on a small device scale a noise will be produced but
not as loud as the actual wind turbine.

3.2.4 Manufacturability Constraints

In the manufacturing process, there are some constraints that became an obstacle.
First of all was the selection of the materials based on the calculations and design. The real
struggle begins on the second obstacle, which was the materials’ properties and their
standards which had to be accepted in the engineering standards. The third obstacle was
the lack of the materials in the kingdom. Finally, the last obstacle was finding proper
workshops to start the manufacturing process.

3.2.5 Sustainability Constraints

Wind energy is not only a clean source of energy but also a renewable sustainable
source. The only downside of wind energy is that having a constant wind speed is not
possible year around. Casual maintenance may be needed, but in the long term as blades
may need to be replaced, while other parts are not expensive to replace or fix.

3.2.6 Engineering Design Standards Constraints

Horizontal axis wind turbine means that the axis of rotation of the wind turbine is
horizontal.

3.2.6.1 HWAT consists of these main parts:

 Blades
 Shaft
 Generator

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 Figure 8: HAWT overview layout

Engineers should always follow the standards which are definition and guide for
how to instruct designers, users, and manufacturers. Standards were invented to guarantee
safety, reliability, productivity, and efficiency in all terms of products that are involved in
engineering components or equipment. It is not mandatory to follow standards, however,
many businesses and companies rely on it because it serves as a regulation. Following the
standards is important for the end user whenever there is maintenance required; because
the user can go to manufacturers that follow the same standard and get replacement parts,
it also makes engineering life easy because everything is calculated in terms of corrosion,
material property, or life of a component. In this design, it is going to follow the standard
to reduce cost, to make the system more user friendly and to avoid manufacturing new
parts that are complicated to manufacture such as generator [11].

Theory and Theoretical Calculation

To fulfill the project, there has to be some calculations that are done prior to the
manufacturing process to insure the required outcome and some afterwards. These
calculations are the Power Coefficient, Swept Area, 𝐴𝑆 , Tip Speed Ratio, 𝜆, Specific Speed
of the Windmill, Cut in Speed, Cut out Speed, Rated Wind Speed, Torque Coefficient, 𝐶𝑡 ,

29 | P a g e
Rotor Solidity, Thrust Coefficients, 𝐶𝑇 , Wind Power, Efficiency in Wind Power
Extraction, Torque Extracted,

Definitions:

1. Power Coefficient:
The power coefficient is the ratio of the actual power output to the theoretical
power in the wind.

Power = Force X Velocity

Force = Rate of change of Momentum

But: Momentum = Mass X Velocity

For a fluid of density (ρ). Flows through a cross-sectional area of A, the mass
flow rate ṁ is given by:

ṁ= ρAV
1
Average Force =2 𝜌𝐴𝑉 2
1
𝐻𝑇 = 𝜌𝐴𝑉 3
2
𝐻𝑊 𝐻𝑊
𝐶𝑃 = = ………………………… (3.1)
𝐻𝑇 0.125 𝜌𝜋𝐷 2 𝑉 3

2. Swept Area, 𝑨𝑺

This is the section of air that encloses the wind turbine or windmill in movement
and interacts with the rotors to produce the rotation motion. For a Horizontal Axis Wind
Turbine (HAWT), the swept area is circular in shape. On the other hand, for a Vertical Axis
Wind Turbine (VAWT) with straight blade, the swept area us rectangular in shape.

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 The swept area for the HAWT is calculated by:

𝟏
𝑨𝑺 = 𝝅𝐷2 …………………………………... (3.2)
𝟒

Where𝑨𝑺 - Swept area (𝑚2 )

D -Rotor Diameter (m)

NOTE: the rotor radius is the distance from the tip of the one blade to the center and the
diameter is twice its length.

3. Tip Speed Ratio, 𝝀

Tip Speed Ratio is ratio of the speed of the windmill rotor tip at radius R when
rotating at
Radians per second to the speed of the wind V m/s. It is numerically represented as:
𝜔𝑅
𝜆= …………………… (3.3)
𝑈0

When the windmill is stationery, the tip speed ratio is zero; this implies that rotor
has stalled. This is experienced when the torque produced by the wind is below the level
needed to overcome the resistance of the load. While with a tip speed ratio of 1, it implies
that the blade tips are moving at the same speed as the wind (the wind’s angle that is ‘seen’
by the blades will be). Whereas at a tip speed ratio of 2, the tips are moving at twice the
speed of the wind and so on.
From empirical results, the optimal tip speed ratio to ensure maximum power
extraction is achieved for a windmill with N blades is:
1𝜔
𝜆 = 4 𝑈𝑅 ……………………. (3.4)
0

4. Specific Speed of the Windmill

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 This is the angular velocity in revolution per minute at which a turbine will
operate if scaled down in geometrical proportion to such a size that will develop unit
power under unit head.

5. Cut in Speed

This is the speed at which the turbine starts to produce any useful power. It this is
the lowest speed at which power develop by the wind turbine 𝐻𝑊 is greater than zero.

6. Cut out Speed

This is the speed at which the turbine stops to produce any useful power. This is
the highest speed at which power develop by the wind turbine is just zero.

7. Rated wind speed

Wind speed at which the rated power is produced, this value defines the shape of
the power curve.

8. Torque Coefficient, 𝑪𝒕

The Torque coefficient is the non-dimensional measure of the torque produced by

a given size of rotor in a given wind speed. This is given as the ratio of the actual Torque
produced to the torque due to the force of the wind on the rotors.
It is represented mathematically by:
𝑇
𝐶𝑡 = 1 2
…………………………. (3.5)
𝜌𝐴𝑠 𝑈0𝑅
2

Where: T- the actual torque produced (Nm)

𝑈0 - Wind Speed (m/s)

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 AS - Swept Area ()σ
R: Radius (m)

9. Rotor Solidity

Solidity of a windmill loosely refers to the proportion of a windmill rotors’ swept

area that is filled with solid blades. This is the ratio of the sum of the width or ‘Chords’ of
all the blades to the circumference of the rotor.
This is represented mathematically by:

NAB
Solidity = ……………………. (3.6)
A𝑠

Where: σ:-Rotor Solidity

N: Number of Blades

AB - Area of one blade (𝑚2 )

A𝑠 : Swept Area (𝑚2 )

10. Thrust Coefficients, 𝑪𝑻

This is non-dimensional measure of the force that falls on the windmill, it is given
as the ratio of the actual thrust force on the windmill to the average force from the wind.
It is represented mathematically as:
1
Force of the wind = 2 𝜌A𝑠 𝑈02

Thrust Force on the windmill.𝐹𝑇 ;

1
FT = C ρA U 2
2 T s 0
FT
∴CT = 1 … … … … … … … … … … … … . . (3.7)
𝜌A𝑠 𝑈02
2

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11. Wind Power

Wind power (𝑃𝑊 ) = Kinetic Energy Per Unit Time

1
= 2 ṁv 2 ……………………………. (3.8)
𝑑𝑚
Where (Mass Flux) ṁ = = 𝜌𝐴𝑉
𝑑𝑡

𝜌 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟 (𝑘𝑔/𝑚3 )

1
Thus Power (𝑃𝑊 ) = 2 𝜌𝐴𝑉 3 Watts ……………………….. (3.9)

Where A = Swept area of blades (𝑚2 )

A = πR2

Where R = Radius of the blade (𝑚)

12. Actual Output Power

P = IV
I: Current in Ampere
V: Voltage

13. Efficiency in Wind Power Extraction

The efficiency in wind power extraction is a function of power CoefficientCP ,

where CP , is the ratio of power extracted by the windmill to the total contained in wind
sources.
𝑃𝑇
𝐶𝑃 = …………………….(3.10)
𝑃𝑊

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Where windmill Power Extracted = PT = PW × CP

1
= 𝜌𝐴𝑉 3 × 𝐶𝑃 (Watts)
2
16
The Betz Limit is the maximum possible value for 𝐶𝑃 which is equal to 27 but the

optimum possible for a multi-blade windmill is 30%.

14. Torque Extracted

In the windmill used for pumping water, Torque output is key.
Torque is given by the ratio power extracted to rotor speed.
P
T= 𝜔T ……………………………………………… (3.11)
𝜆𝑣
Rotor Speed ω = 𝑅

Where v = wind Speed (m/s)

𝜆 = Tip speed Ratio
R= length of blade (m)

PT
Thus: T= 𝜆𝑣⁄ ……………….... (3.12)
𝑅
1
But PT == 𝜌𝜋𝑅 2 𝑉 3 × 𝐶𝑃 (Watts)
2

1
𝜌𝜋𝑅 2 𝑉 3 ×𝐶𝑃
Therefore: T=2 𝜆𝑣⁄
𝑅
1 𝜌𝜋𝑅 2 𝑉 3
T=2 𝑉 2 𝐶𝑃 (Nm) ……………………………………… (3.13)
𝜆

The two main components in mechanical power are force and speed. Torque is
twisting or turning force and pumping requires a lot of torque particularly when starting
off from on idle state. Generators used for power production on the other hand require a
lot of speed. The power might be the same but the pump and generator will utilize this
power differently. The power from the rotator is a function of both torque and rotation per
minute (angular velocity of the rotators). The following table shows the typical choices

35 | P a g e
for the tip speed ratio and blade number for the case pump (windmill) and generators (wind
turbine).

Table 4: tip speed ration vs number of blades

Tip Speed Ratio Number of blades Function

1 6-20 Slow pumps

2 4-12 Faster pumps

3 3-6 Dutch 4-bladed

4 2-4 Slow generators

5-8 2-3 Generator

8-15 1-2 Fastest possible

Product Subsystems and selection of Components

Base

The base was also manufactured form using same material as the tower “Stainless
Steel ase 304” with a hole in the center to install the tower. The bridge must be able
to sustain all of the weight starting from the tower and ending with the five blade

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 Figure 9: base design

3.4.2: Tower
Base and tower manufacturing or selection plays an essential role of the wind turbine
design as the bridge and tower must be able to withstand the external force and vertical
load. The external force being the wind energy and the vertical load is what will be installed
on the tower starting from the shaft, bearings, rotor and blades. The tower is 1.5 m in height
with thickness of 3 mm. Material used in manufacturing this tower is with accordance to

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engineering standards where “Stainless Steel ase 304” was used. The water tank is a regular
tank with capacity of one gallon bought from local grocery stores.

Figure 10: Tower

3.4.3 Bearing
There is different type of bearing like needle bearings, ball bearings and roller bearings.
Base on the selected shaft which has inner diameter of 17mm and outer diameter of 40mm
ball bearing was selected according to sanders in figure 11.

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Figure 11: baring design

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 Table 5: Bearing Standards

[29]

3.4.4 Blade

Horizontal blades are a crucial and basic part of a wind turbine figure 3.1& figure 3.2. They
are mainly made of fiber glass, carbon fiber or aluminum alloy. We selected Carbon Fiber
because it is light weight and carbon fiber has high strengths.

Overall design of the rotor affects by the design of blades. Rotor blades take the energy out
of the wind and convert its kinetic energy into the rotation of the hub. For this project the
group decided to go with five blades because the wind speed in the region is low so five
blade will rotate easier than the 3 blades, but the issue is with having more blades the
vibration will increased and the torque will be less.

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 Figure 12: individual blade

Figure 13: five blades assembly

3.4.5 Generator
A wind turbine generator is one that is used to help convert the wind power into an
electrical one to operate the windmill and it represents an automatic module for the pitch
angle of the windmill’s blades making a regular output in result. [30]. For this project,
the chosen wind turbine generator was The Missouri Wind and Solar power generator,
which is one that is considered a new innovation in the generator’s line. It can produce up
to 2800 watts and has a dual rotor and stator and it is aimed to provide the windmill a

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hydroelectric power. It was used because it is found to be suitable for the design and
standards due to how smooth it rotates. [31]

Figure 14: generator

Table 6: Watts VS Wind speed

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3.4.6 Charge Controller

A charge controller act as a regulator that limits the rate at which electric current is
added to or drawn from the batteries. Its job is to prevent overcharging and may
protect against overcharge which can lower the battery life or performance [35].

Figure 15: Charge Controller

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3.4.7 Battery

The battery that is used for the project is The Long WPL150-12N rechargeable power
guard, which is, sealed lead acidic battery as shown in figure 16 and table 7

Figure 16: Battery

Table 7: Battery Specification

Brand Long
Weight 4.5 kg
Capacity 150Ah
Dimension 19.02 x 6.7 x 9.5
Maximum Discharge Current For (5 1500A
Seconds)
Maximum Charging Current For (5 45A
Seconds)
Design Life 12 Years

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3.4.8 Voltmeter

A Voltmeter is a device or instrument that is aimed to measure electrical voltages’

variations between two points or measures electrical potential in electrical circuits. [32].
It works by having a scale that shows readings once a variation happens. There are
different types of voltmeters with different usages. The one used for this project is the
Digital Voltmeter and it was used to measure the electrical voltages in the generator used
as a major component of the windmill. [33]

Figure 17: voltmeter

3.4.9 Anemometer:
The device we selected is Proster TL017 Handheld Anemometer Wind Speed Meter Scale
Gauge. This device basically used for some parameters such as wind speed and air
temperature. It has a large LCD display with backlight which makes it readable. This
device is ideal for the outdoor activities such as windsurfing. With the help of the device,

45 | P a g e
we will calculate the wind speed to get the actual power and compare it with the theoretical
power [34].
Specification:
Powered by a 3V CR2032 battery
Thermometer: NTC Thermometer
Operating Humidity: less than or equal to 90%RH
Storage Temperature: -40~60 centigrade, -40~140F
Current Consumption: About 3mA
Item Size: 105 * 40 * 18mm
Item weight: 50g
Air Velocity:
Range: 0 – 30m/s, 0 – 90km/h, 0 – 5860ft/min, 0 – 65mph, 0 – 55Knots
Resolution: 0.1m/s, 0.3km/h, 19ft/min, 0.2mph, 0.2Knots
Threshold: 0.1m/s, 0.3km/h, 39ft/min, 0.2mph, 0.1Knots
Accuracy: ± 5%
Air Temperature:
Range: -10 – 45 centigrade, 14 – 113F
Resolution: 0.2 centigrade, 0.36F
Accuracy: ± 2 centigrade, ± 3.6F

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 Figure18: Anemometer

3.4.10 Tachometer

This Digital tachometer is a high-quality instrument to measure the Rotational Speed

(RPM) with wide measuring range and high resolution. It's featured with high accuracy
measurement, quick measuring time and long detecting distance up to 500 mm (20" inches)
with Laser.
Features:
 Large LCD displaying Screen

 Wide measuring range & high resolution. The use of durable.

 The last value/min. value will be automatically stored in memory and can be
displayed by turn anytime.

 The RPM of motors and machine parts.

 The housing has been carefully shaped to fit comfortably in either hand.

 Digital display gives exact RPM with on guessing or errors. It is a great tool to
measure

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 In wood and metal working it can be used to accurately measure the speed of a
lathe.

Specification:
 Display: 5 digits, 18 mm (0.7” inch) LCD with Function Annunciation

 Testing Range: 2.5 ~ 99,999 RPM (rate / min)

Resolution:
 0.1 RPM (2.5 ~ 999.9 RPM)

 1 RPM (over 1,000 RPM)

 Accuracy: ±(0.05 % + 1 digit)

 Sampling Time: 0.8 seconds (over 60 RPM)

 Test Range Selection: Automatic

 Memory: Maximum value, Minimum value and Last Measured value

 Detecting Distance: 50 ~ 500 mm (2 ~ 20 inch) (Laser)

 Time base: Quartz Crystal

 Circuit: Exclusive one-chip of microcomputer LSI circuit

 Power: 9V PP3 Battery (not included)

 Operating Temperature: 0 ~ 50 °C (32 ~ 122 °F)

 Dimension: approx. 131 (L) x 70 (W) x 29 (D) mm (5.16’ x 2.76’ x 1.14’ inch)

 Weight: approx. 160g

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 Figure19: Tachometer

3.4.11 Water Pump

Is mechanical device that moves fluid or gas by pressure or suction. The pump used in this
project is a small 12 V pump with 1100 GPH, it’s made of stainless steel shaft. The pump
also ignition protected and submersible. For this project the pump starts after the generator
provide it with power while the pump placed in the bottom of the tank and its carry the
water through plastic pipe to move the water into the second tank.

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 Figure 20 : Water Pump

Table 8: Water Pump Specifications

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3.4.12 Water Tank

The water tank is a regular tank with capacity of one gallon bought from local grocery
stores. There will be two water tank one full of water and an empty one. One will be used
for pumping water and the other for storing it.

Figure 21: Water Tank

3.5 Manufacturing and assembly (Implementation)

The base and tower of the wind turbine will be manufactured according to the
figures above in section 3.4. Bearing will be chosen in accordance with engineering
standards of SKF. Shaft will also meet ASME engineering standards. Generator, blades
and pump will be selected according to the engineering standards and purchased.

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 4 Chapter 4: System Testing and Analysis

THEORETICAL WIND TURBINE POWER CALCULATION

The most important factors of the calculation are:

 speed of air (velocity)
 mass of air (density)
 area of the blade (swept area)

The power calculated by equation (3.9) in page 35

1
(𝑃𝑊 ) = 2 𝜌𝐴𝑉 3

Where:
P: power in watts
𝑘𝑔
ρ: air density approximately 1.2𝑚3

A: swept area which can calculated by equation (3.2) in page 32

𝟏
𝑨𝑺 = 𝝅𝐷2
𝟒
𝑚
𝑣 3 : wind speed in 𝑠

Cp: Power coefficient, usually varies according to wind turbine design, ranging
between 0.05 and 0.45.
Wind velocity is the only various in this equation. Table 9 and figure 22 is
represent the theoretical power in the windmill at different air velocity:

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 Table9: theoretical gain power calculation

Theoretical Gained Power Calculation

Density ρ Area A Wind speed v power coefficient cp power
1.2 1.5393 1 0.2836 0.261927
1.2 1.5393 2 0.2836 2.095418
1.2 1.5393 3 0.2836 7.072037
1.2 1.5393 4 0.2836 16.76335
1.2 1.5393 5 0.2836 32.74091
1.2 1.5393 6 0.2836 56.57629
1.2 1.5393 7 0.2836 89.84106
1.2 1.5393 8 0.2836 134.1068
1.2 1.5393 9 0.2836 190.945
1.2 1.5393 10 0.2836 261.9273

Figure 22: power calculation

Theoretical Turbine Gained Power

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 EXPERIMENTAL WIND TURBINE POWER CALCULATION

After designing the windmill system and selected material for the all parts. In order to
test the power output of the windmill and compare it with the theoretical result which
provided in chapter 3. Result for the windmill was taken in special set up.
Testing was taking in Al Dammam, which was basically in an open area. A lot of devices
were used in our project such as, anemometer, tachometer and voltmeter. The purpose of
using these devices is to find the power output of the windmill by using equation [3.12]
P = IV
The Result below represents the data taken from the experiment.

Table 10: Experimental data

Experimental Reading
voltage( current
wind speed (m/s) v) (A) revolution(RPM) power (watt)
7.59 10 4 150 40
8.94 23 5 300 115
12.07 43 8 500 344
20.56 46 9 750 414
24.58 60 12 1000 720

Figure 23: Calculated power

power (watt) vs wind speed (m/s)

800
700
600
500
400
power (watt)
300
200
100
0
7.59 8.94 12.07 13.45 14.69

54 | P a g e
 Results, analysis and discussion

As a result, the experiment shows the difference between power output in

theoretical and experimental which are represented as graph and table above. Noticed that,
there is a gap between theoretical and actual power output as expected due to several
factors. These factor are human error, manufacturing error, device reading error and drag
error. The percentage of error between 10% to 60%. Another reason for this gap is the
friction develops in the surface of the blades. The tower elevation plays an important role
as well. In addition, unexpected vibration happened led to disturb Conservative of the wind
energy. These are the most important factors that may justify the difference between two
readings. The number of blades used is 5 with a total surface area of 0.24628 m2 and this
gives a solidity of 0.8, the minimum (optimum) value of solidity for a windmill and
therefore ensures conformity with the standard specifications. Bearings are subject to very
high heat losses due to friction and this will be greatly minimized by application of oil and
grease and therefore greatly improving the
efficiency.
All materials used are either locally available or easy to order from The United States
and at a low cost making the model economically viable.

Table 11: Theoretical Vs Experimental data

Theoretical vs Actual Reading

Density ρ Area A Wind speed v power coefficient cp theoretical power power (watt)
1.2 1.5393 7.59 0.2836 114.5265225 40
1.2 1.5393 8.94 0.2836 187.1514958 115
1.2 1.5393 12.07 0.2836 460.5773287 344
1.2 1.5393 13.45 0.2836 637.3054014 414
1.2 1.5393 14.69 0.2836 830.3212135 720

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 Figure 24: Theoretical Vs Experimental

900

800

700

600

500
Theoretical power(watt)
400 Experimental power (watt)

300

200

100

0
7.59 8.94 12.07 13,45 14.69

Goals

The main factor to be considered in this experiment is wind speed. In order for
water to be pumped the turbine needs a minimum wind speed of 8 mph or 12.8 kmh. If no
sufficient wind is existed an air blower is used to provide a sufficient wind speed for the
purpose of testing the device.

Experimental methodology

Numerous tools and devices were used in order to test the system and they are as follows

1. Anemometer: a device used for measuring wind speed

2. Tachometer: A device used to measure the rpm of the moving rotor.

3. Air blower: used in case no sufficient wind is available.

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4. Water tanks: two water tanks one full and one empty with a hose to be connected
through a whole between the two tanks for fluid transfer.

5. Water pump: to pump water for a tank to another using the wind energy.

6. Generator: providing power output that will operate the water pump

7. Charge control: is a device used to provide a constant voltage to the pump as a safety
procedure so the generator will not overcharge the pump and damage it.

Procedure

The device is located at an open area away from walls or any objects that might
block the wind. Anemometer device is installed or set near the turbine blades to measure
wind speed. If no sufficient wind available, the air blower will be used for testing purpose.
Tachometer laser will be pointed at the rotor for 1 minute to measure the rotor’s revolution
per minute. After the blade’s rotation the rotor will rotate causing the shaft to rotate and
power will be generated. Power is transferred though wires to the charge control and then
to the pump. Finally, water will be pumped from one tank to another. Data will be recorded
from tachometer, anemometer and voltmeter.

57 | P a g e
 5 Chapter 5: Project Management

5.1 Project Plan

As group started to work on this project from the beginning of the semester until
the end of it, with limited period of the semester giving a limited time to work on each task
which had to be divided between each one of the five members so that the work can be
completed before the deadlines. The following table describes the tasks and the time period
each team member was given to complete.

Table 12: Duration of the tasks

No. tasks start date finish data days to

complete

1 introduction 2/8/2018 2/10/2018 2

Project
background

2 3

Previous
Literature Work 2/10/2018 2/13/2018
Review Comparative
study

58 | P a g e
 Advantages
and
disadvantages
of windmill

design of base

3 System Design design of

Solid works rotor 3/13/2018 3/15/2018 2

`design of
tower
design of
bearing
calculation of
power
4 calculation of
Design
torque
Methodology
calculation of 3/15/2018 3/17/2018 2

mass flow rate

calculation of
swept Area

5 Material Selection 3/18/2018 3/21/2018 3

59 | P a g e
 6 System Testing and Analysis 4/10/2018 4/15/2018 5

Conclusions and Future 4/20/2018 4/24/2018 4

Recommendations
7

5.2 Contribution of Team

To finish the project on time, each member worked on a certain task and some
times more than one worked on the same task and other time the whole group
worked on one certain task. The following table clarifies which tasks were given for
whom.

Table 13: Tasks distribution

No. tasks Assigned to Contribution

Abdulhadi 20%

1 Hussain 20%

introduction
Mohammed 20%

Yousef 20%

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 Yassin 20%

Project
background
Yassin 100%
Abdulhadi

Literature
Review

Previous Work Yousef

Mohammed 100%
Comparative Hussain 100%
study Abdulhadi
Advantages and Yousef
disadvantages of Yassin 100%
windmill

design of base Yassin 100%

3 System Design
solid works
design of rotor Yousef 100%
Hussain

design of tower Yousef 100%

Yassin

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 design of bearing Yousef 100%
Abdullhadi

calculation of
power
4 calculation of
Design
torque
Methodology
calculation of Mohammed 100%

mass flow rate

calculation of
swept Area
Yousef

5 Material Selection Hussain 100%

Yassin

Abdulhadi

Yousef

6 System Testing and Analysis Hussain 100%

Yassin

Abdulhadi

Conclusions Hussain 100%

7 Mohammad

Abdulhadi

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 8 Future Recommendations Yassain 100%

Yousef

5.3 Project Execution Monitoring

As students who had other projects and Assignments to work on, having a timetable
and an agenda to follow was a must.

Table 14: Table of activities

Time Assignments

Twice a month Assessment class

Weekly Group Meeting

Twice a month Advisor Meeting

Tue, March 4 Midterm presentation

Test the system

May,3rd Final presentation

5.4 Challenging and Decision Making

During the senior project development, few difficulties and issues were seen, such
as the following:
6 Material standard and equipment resourcing.
7 Manufacturing to the design specification.
8 Report writing and documenting.

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5.4.1 Material and equipment resourcing

Based on the needs of this project, buying some materials from local stores was
required, and some from international stores. Problems with both local and international
stores were faced due to shipping.

 Wind turbine generator.

One of the most important parts of the project was the generator. Initially, it was
planned to buy a generator from local stores, but there was no luck finding a generator that
will give the power output needed for low revolution per minute. Moreover, the best chance
was to order a generator that was specifically made for wind turbines, which meant that it
is a must to find a way to ship it. It was such a challenge to find a store that shipped
internationally, thus, an address account in the United States of America was opened to
ship the generator directly from there to Saudi Arabia, and this was the solution in hand.
However, another problem with the shipping company was faced where they had not
updated the tracking number and the shipment was nowhere to be found, so, it was
necessary to deal with the shipping company for one month to get the package.

 Blades.
Another challenge was to manufacture the blades that were designed using the solid
works. The big composite material shops were so busy making big projects such as water
tanks which meant that this project was not a priority or aim for them, on the other hand
the small composite shops are usually controlled by none Saudis whom don’t speak English
nor Arabic very well, so it was hard to explain to them the specification and angle or the
blades without having an actual sample and the solution found was to buy a similar blade
to the specification and use it for testing. Doing so led to insure that manufacturing errors
got avoided and saved money.

 Water pump.

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 After searching for a 12-volt pump in local stores, there was no luck finding one,
and so online shopping was the alternative and a pump that is compatible with the system
design and calculations was purchased. It was better to order the pump online rather than
having to buy a 24-volt pump that had to have an additional a converter in order to make it
work and operate.

 Material Standard.
One of the challenges was to buy the material from big companies as no company
was willing to sell a small quantity of what they have. For example, to buy a stainless-steel
pipe, companies were not willing to cut a section for the length that was required. They
claimed that ten meters had to be bought then cut it to the length needed. Another example,
when to buying some aluminum sheets for the tail section of the wind turbine, they only
offer a big sheet of aluminum. These problems caused a huge waste of materials, and the
solution found was to go to one of the blacksmithing shops that buy their material from the
same big company that supply the materials and use their left over materials to design the
project based on the chosen standards.

5.4.2 Design problems

One of the main issues that have been seen during manufacturing the design was
that the solid works design was a bit complicated in shape, for example, while
manufacturing the base of the tower and the case, the shop worker mentioned that design
required machinery process using the latest machine and welding, so, the given advice was
to simplify the system more in order to reduce the cost and labor cost. The direction was
followed because it was better cost-wise, time-wise and had no effect on the performance
or durability of the overall design.

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5.4.3 Report writing and document
Due to the fact that the report was written by all members, it was obvious
that some were stronger than other in making sentences and grammar.
Therefore, the solution in order to make the report appear more professional was
as follows:

1- Each graph written by a member is checked by the other members.

2- Check with the advisor, and co-advisor before submission.
3- Show the instructor a draft before submission.
By doing so, the problem of the report being written by different people was solved,
which meant mistakes chances are decreased.
Material and equipment resourcing (purchasing)

The project needs many things to purchase either from local stores or international
stores. Variety of difficulties were faced a variety of difficulties during the start purchasing
of the parts needed. Some difficulties were:

 International stores.
The most important part of this project is silica gel, so the group looked for the local
stores that distribute silica gel, but did not find a local store that has this specific kind of
silica gel. The problem that was faced was that most of the international stores could not
deliver the silica gel to Saudi Arabia, because of that time was consumed to find a solution
for this problem. The solution which was decided was to deliver the material to Bahrain
and then send it from Bahrain to Saudi Arabia. By this solution, the silica gel made it to
Saudi Arabia.

 Motor has specific speed.

A challenge that was faced also was when the group decided to buy a motor and started
looking for a motor that has a specific speed based on the made calculations. But a motor
that meets the requirements was not found. The solution was a speed control that can be

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used to control the speed. So the group decided to buy this speed control to solve this
problem.

 Heat source.
At the beginning, the members of the group planned to use a solar panel to produce the
heat that required to dry the silica gel. But unfortunately, the short of time prevented
building the solar panel system. So it was decided to use an electric heater instead of solar
panel system.

5.5 Project Bill of Materials and Budget

Table 10 provides the costs of all the materials and equipment that were purchased
and manufactured.

Table 15: List of material and their cost

Material Cost (SR)

Generator 1400
Blades 1200
Pipe 400
Stainless-steel 300
Water pump 450
Wires 89
Battery 380
Charge controller 600
On off switch 56
Bearing 350
Aluminum 250
Water house 15

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 Water tank 24
Hardware 90
Tachometer Rpm Speed Kit 300
Anemometer Digital LCD 340
Voltmeter 115

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 6 Chapter 6: Project Analysis

Life Long Learning

The senior design project did not only examine the team’s engineering skills, but also
played a major role in developing other technical and non-technical skills. One of the main
aspects that developed the team member’s time management skills is the tight schedule of
this semester, where the team had to do many challenging tasks in a very short period of
time. This also enhanced the ability of each team member to work efficiently as a team and
encourage every individual to do a quality and a professional work.

Improve our Skills in Some Software Tools

The project required using many software’s, some of the team members were
familiar with and other not quite. The senior design project developed the team’s skills in
designing as it was not easy to design the wind turbine. Other software’s such as Microsoft
Word, Excel and Microsoft PowerPoint were essential in the team’s development. Some
software’s were already known and familiar to the team but the skills and knowledge
required for them did substantially increase and develop.

Time Management Skill

Time management skill is the most important skill that is learnt through university
life. Team can achieve great outcome just by managing time of every individual member
of the team. When there is a need to achieve a certain goal in a specific time, the jobs get
divided to every member of the team to do it on his time within the range of time put in
GANTTS chart. Off course, a lot of difficulty to do the job in specific time were faced,
because of them, skills to manage the time on daily basis was developed. GANTTS chart
was used to organize the time and tasks that must be done in the project life. GANTTS
chart is one useful tool that has been used in this project to organize time of starting and
ending task.

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 Problem Solving

While working on the project, many problems were faced but got solved
eventually. These problems provided some skills, knowledge and experience of how to
handle problems to find the appropriate solutions within a minimum time. Many issues
required the use of critical thinking skills to solve, such as to select the right materials,
tools, design, find good machinist and the purchase of some tools from abroad. In fact,
these problems made the team gain experience to face any future obstacles in the project.

Impact of Engineering Solutions

The project achieved great impact on the social, environment, and economy. Each
impact is explained in details next.

6.2.1 Social

Here comes one of the important sources that had to be taken into consideration,
which is the impact of the society. The main goal basically is to provide good and healthy
Impact on the society. There are several applications for the project to be used, for
example; telecom towers, offshore platforms and other purposes that require energy
where there is no electric grid.

6.2.2 Environment

Wind turbine is increasingly being used worldwide as an important contribution

to renewable energy. The development of this project might lead to environment impacts,
such as noise pollution, bird and bat fatalities, greenhouse gas emissions and land surface
impacts. This project is going to provide a good impact to prevent all these problems.

6.2.3 Economy

Regarding the project’s impact on the economical point of view, it costs a huge
amount of money, but in the project selected a small scale and it simplified the
components and made it a little bit affordable for the students.

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6.3 Contemporary Issues Addressed

Electricity and pumping water are really hard to find in some places such as Saudi
Arabia, especially in the remote area. According to this problem, the group designed the
project to fix this issue by pumping water through an electrical pump via the power that
comes from the wind.

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 7 Chapter 7: Conclusion

Conclusion

Throughout human’s life, change and development was always an aspiration, a goal
to be reached. Thus, many efforts and support has been given to enrich research and
development, which is why researchers and innovators have always been valued, where
the changes they help making or make themselves affect lives all over the world. They
affect economy, science, politics and more. They save lives and they change a way of living
for good, one example is the generation that once lived without a cooling system but cannot
spend a day in the nature’s temperature today. To be more specific, power generation was
developed through research and innovations until it became a major concern due to its
effect on counties, societies, individuals and the whole earth in general. For that reason,
power generation is valuable, especially nowadays where changes on the nature is noticed
and its result on economy and politics are the most critical.

Taking the demand for power generation and its effect on the quality of life in
consideration, the group decided to go for a project that is concerned with power generation
and how mechanics can be utilized to develop sustainable energy as it is also the aim of
the countries to have, where governments are searching for new ways to reserve energy.
Saudi Arabia in particular stated it as one of its aims of 2030’s vision; to have sustainable
energy. So, the project’s idea should be a problem solver for governments and counties in
addition to a savior for environments and a profit for developers.

For the facts surrounding the need for sustainable power generation systems, the
group has thought of this project as a key for future paths. Also due to the fact that previous
research has been made on the same idea of Windmills, having references was an addition
to the reason of choosing the project.

Where references existed, the group have decided to build their system based on
studying the previous researches and experiences to better understand the mechanics but

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the group based some of the calculations based on the chosen materials and methods after
a full research was made. In addition, the built Windmill system had to be tested in local
environment, thus, the choices of materials and methods had to be suitable for the
environment where the Windmill is to be used at, which is in Saudi Arabia, so it was based
on the climate of Saudi, its Government regulations and the suitable areas after full research
was done on climates of critical locations in Saudi where every climate factor was taken
into consideration, such as humidity as it differs from one area to the other. Moreover,
choice of materials that followed the Engineering standards was also a major concern.

Moreover, the group chose the Horizontal Axis Wind Turbine because it is more
likely to utilize as much wind as possible to guarantee energy supply at all times.

On the other hand, other than the group’s evaluation of the advantages and
disadvantages of the Windmill and analyzing the constraints, the group made sure to follow
correct Calculations and theories to guarantee best results and most benefit. So, Power
Coefficient, Swept Area, 𝐴𝑆 , Tip Speed Ratio, 𝜆, Specific Speed of the Windmill, Cut in
Speed, Cut out Speed, Rated Wind Speed, Torque Coefficient, 𝐶𝑡 , Rotor Solidity, Thrust
Coefficients, 𝐶𝑇 , Wind Power, Efficiency in Wind Power Extraction, Torque Extracted
were separately explained, measured and calculated to ensure all desirable results.

Once the system was built, it was tested, results were noted down and correction
were made where needed and every aspect was analyzed and stated for evidence and future
reference.

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 Future Recommendation

After doing the testing, analyzing the result, and along with the average wind speed
in Saudi Arabia. The recommendation for those who want to do future studies on horizontal
wind turbine system is that the more number of blades added the more torque and
revolution at slower wind speeds. Another recommendation would be adding a solar system
along with wind turbine so the solar system charge the batteries in case there is no wind,
and the wind turbine charge the battery in case there is no sun. the average speed for Saudi
Arabia is 5.5 in the eastern provenance. another recommendation is to place the wind
turbine in higher or longer tower so that more power output is gained according to the
comparative study mentioned in chapter tow. Another recommendation would be to
improve the design by making it more aerodynamic to get the most out of the winds by
improving the design of the tip and the design of the tail.

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 8 References

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9 Appendix A: CAD drawings

full system design

base design

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 blade design

lower case design

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washer design

housing design

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Rotor

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