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Design and Construction of a Mini-Hydrodynamic generator

Conference Paper · December 2016

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 International Conference on Mechanical, Industrial and Energy Engineering 2016
26-27 December, 2016, Khulna, BANGLADESH

ICIMIE-MC-160356
Design and Construction of a Mini-Hydrodynamic generator
Md. Golam Kader1,Md. Sourove Akther Momin 2,*, Mihir Dutta3 ,Md.Sahid Hassan4,Ariful Hossen5
Department of Mechanical Engineering, Khulna University of Engineering & Technology, Khulna-9203, BANGLADESH

ABSTRACT
In the field of power generation, hydro electrical power plant has a great contribution in the world. It is popular due to having
efficient and reliable form of clean source of renewable energy. It can be an excellent method of harnessing renewable energy
from small rivers and streams. The mini-hydro project designed to be a run -of-river type, because it requires very little or no
reservoir in order to power the turbine. The water will run straight through the turbine and back into the river or stream to use it
for the other purposes. This has a minimal environmental impact on the local ecosystem. In this project, the basic concept of
hydro power generation is shown. A proto type turbine was designed by Solid Works software. The turbine power and speed
were directly proportional with the site head, but there were specific points for maximum turbine power and speed with the
variation of the site water flow rate. Turbine is rotated by using the thrust of water of velocity of water. Two dynamo is
attached with turbine shaft and so rotation of turbine is the result in rotation of both dynamo. This concept highly increase the
overall efficiency. Power generation by this mini hydro power generator is calculated. To the sum up, it can be said that if this
concept will be applied in the Hydro power plant, the output of power generation will be increase.

Keywords: Hydro electric power plant; Renewable Energy; Solid Works; Generator

1. Introduction converts this mechanical energy into electrical energy

Hydropower is an extremely flexible technology for [5].
power generation. Hydro reservoirs provide built-in
energy storage, and the fast response time of hydropower 2. Overview of Hydro Electric Power Plant
enables it to be used to optimize electricity production 2.1 Historical Background
across grids, meeting sudden fluctuations in demands. Humans have been harnessing water to perform work
However, large scale hydropower projects can be for thousands of years. The Greeks used water wheels
controversial because they affect water availability for grinding wheat into flour more than 2,000 years ago.
downstream, inundate valuable ecosystems and may The evolution of the modern hydropower turbine began
require the relocations of populations[3]. Despite being a in the mid-1700s when a French hydraulic and military
mature technology, in comparison with other renewable engineer, Bernard Forest de Bélidor wrote Architecture
energy sources, hydropower has still a significant Hydraulique . In 1880[3], a dynamo driven by a water
potential. New plants can be developed and old ones turbine was used to provide arc lighting– a technique
upgraded, especially in terms of increasing efficiency and where an electric spark in the air between two
electricity production as well as environmental conductors produces a light – to a theatre and storefront
performance. In particular, the development of low-head in Grand Rapids, Michigan, and in 1881, a dynamo
or very low-head small hydro plants holds much promise. connected to a turbine in a flour mill provided street
The hydro-power plants can be classified as below lighting at Niagara Falls, New York; both of which used
direct current technology. The breakthrough of
l. Storage plant alternating current, the method used today, allowed
( a) High head plants power to be transmitted longer distances and ushered in
( b) Low head plants the first U.S. commercial
( c ) Medium head plants.
2. Run-of-river power plants
( a) With pond age
( b) Without poundage.
3. Pumped storage power Plants[1].

Hydro-electric power is a form of renewable energy

resource, which comes from the flowing water. To
generate electricity, water must be in motion. When the
water is falling by the force of gravity, its potential
energy converts into kinetic energy. This kinetic energy
of the flowing water turns blades or vanes in a hydraulic
turbines, the form of energy is changed to mechanical
energy. The turbine turns the generator rotor which then Fig.1 Ancient concept to generate electricity from water

* Corresponding author. Tel.: +88-01738373182

E-mail address: [email protected]
installation of an alternating current hydropower plant at o No ash & flue gas problem & does not pollute
the Redlands Power Plant in California in 1893[1]. The the atmosphere.
Redlands Power Plant utilized Pelton waterwheels o The plant efficiency does not changes with age.
driven by water taken from the nearby Mill Creek and a o It takes few minutes to run & synchronize the
3-phase generator which ensured consistent power plant.
delivery. The past century of hydropower has seen a o Can easily work during high peak daily loads.
number of hydroelectric advancements that have helped o These plants are used for flood control &
it become an integral part of the renewable energy mix irrigation purpose.
in the United States. Find out more about the last 100
years of hydropower with this timeline [2]. 2.4 Hydropower prospects in the Himalayan countries
Table -1 Tabular information about the prospects in the
2.2 Hydroelectric Power generation Himalayan countries of hydropower [3].
o 675,000 MW of hydro-electricity Country Installed Hydropow Hydropo
o approximately 20% of the world’s electricity Generation er wer
o accounting for about 88% of electricity from Capacity Developed Potential
renewable sources. (MW) (MW) (MW)
Bangladesh 4,120 218 755
2.2.1 Itapúa power plant
o Largest hydroelectric power plant in the world Bhutan 481 469 23,670/3
o Located between Brazil and Paraguay. 0,000
o Can generate 12,600 MW of power.
o Height of the dam reaches 196 meter and the India 124,287 32,300 84,000/1
length 7.76 km. 50,000
o Lake created by the project spreads over 1,350
Nepal 684 627 43,000/8
sq. km and contains 29 billion tons of water.
3,000
o Cost of the project stands at US$20 billion.

2.2.2 Hydroelectric power Plant in U.S.A 2.5 Disadvantages of hydroelectric power generation
Hydroelectric power stations in the United States are o Disrupts the aquatic ecosystems.
currently the largest producer of renewable power in the o Disruption in the surrounding areas.
U.S. Hydroelectric power produced 66.8% of the total o Requires large areas.
renewable power in the U.S. in 2008, and 6.4% of the o Large scale human displacement.
total electricity[3]. o Very high capital cost or investment.
o High quality construction.
2.2.3 Hydropower prospects in Bangladesh o Site specific.
o Flat terrain - limited potential 3. Constituents of Hydroelectric Power Station
o The rivers in the CHT hold such potentials. Water driven structures in a hydro electric control
o Kaptai on Karnafuli river generating 218 MW station incorporate dam ,spillways , head works, surge
of power. tank, penstock and extra works.
o Other potential rivers are Matamuhuri and
Sangu. 3.1 Dam
A dam is a hindrance which stores water and makes
2.2.4 Tipaimukh dam water head. Dams are worked of concrete or stone
o Located on the Barak River in Manipur State masonry, earth or shake fill. This sort and game plans
of India Multi-purpose - electricity generation rely on the geography of the site. A masonry dam might
and flood control be based on a contract canyon. An earth dam might be
o Electricity generation capacity - 1500 MW most appropriate for a wide valley. The kind of dam
o Risk of dam failure likewise relies on the establishment conditions, local
o Impact on haor eco-system. material and transportations available, occurrence of
earth tremors what's more, other hazards.at the vast
2.2.5 Karnafuli Hydro Power Station majority of destinations more than one kind of dam is
o 230 MW generation capacity appropriate and the one which is most efficient is picked.
o Reservoir size is 777 sq. km
o Economic development 3.2 Spillways
o Social disruption There are times in which the waterway surpasses the
capacity limit of the supply. Such a circumstance
2.3 Advantages of hydroelectric power generation emerges amid substantial precipitation in the catchment
o No fuel required. territory. To release the overflow water from the
o Less supervising staff is required. capacity supply into the stream on the down stream side
o Cost of electricity is constant. of the dam spillways are utilized. Spillways are

ICMIEE-MC-160356- 2
developed of solid wharfs on the top of the dam. Doors 3.5 Penstocks
are given between these wharfs and surplus water is Penstocks are opened or shut courses which convey
released over the peak of the dam by opening of these water to the turbines. They are by and large made of
doors. strengthened cement or steel. Concrete penstocks are
reasonable for low heads(<30m)as awesome weight
causes fast crumbling of cement. The steel penstocks
can be intended for any head, the thickness of penstock
increments with the head or working weight, Different
gadgets, for example, programmed butterfly valve, air
valve and surge tank are accommodated the insurance of
penstocks. Programmed butterfly valve stop water move
through the penstock instantly when it raptures . Air
valve keeps up the air weight inside within the penstock
equivalent to the barometrical weight. At the point when
water comes up short on a penstock quicker than it
enters, a vacuum is made which may bring about the
penstock to collapse. Under such situations, air valve
opens and concedes air in the penstock to keep up inside
pneumatic stress equivalent to the outside pneumatic
stress.

Fig 2. Hydroelectric dam cross-section diagram

3.3 Head Works

The headwork’s comprises of the preoccupation
structures at the leader of an admission. They by and
large incorporate blasts and racks for occupying
skimming debris, sluices for by-passing flotsam and
jetsam and silt and valves for controlling the stream of
water to the turbine. The stream of water into what's
more, through headwork’s ought to be as smooth as
conceivable to keep away from head loss and cavitation.
For this purpose, it is important to keep away from
sharp corners and sudden withdrawals or amplifications.

3.4 Surge Tank

Open channels driving water to the turbine require no
security. Notwithstanding, at the point when shut
channels are used, protection ended up important to
restrict the irregular weight in the conduit. For this
reason, closed channels are dependably given a surge
tank. A surge tank is a little store of tank(open at the
top) in which water level ascents or tumbles to decrease Fig 3. Hydraulic turbine
weight swings in the channel. A surge tank is situated
close to the start of the channel. At the point when the 4. Theory:
turbine is running at an unfaltering load, there are no Here, we consider that the revolution per minute(N) of
surges in the stream of water through the conductor i.e. the turbine blade has to determine.
the amount of water streaming through the conductor is When our output from turbine P is fixed.
only adequate to meet the turbine necessities. However, We know,
when the heap on the turbine decreases, the senator Overall efficiency of turbine = mechanical efficiency ×
shuts the doors of the turbine, reducing water supply to hydraulic efficiency × volumetric efficiency
the turbine. The overabundance water at the lower end
of the conductor surges back to the surge tank and Or, Ƞ0=Ƞm× Ƞh× Ƞv (1)
expands the water level. In this manner the conductor is
kept from bursting. On the other hand when the heap on Here, Ƞv is the ration of the quantity of water actually
the turbine builds, extra water is drawn from the surge striking the wade to the quantity of water supplied to the
tank to meet the expanded load prerequisites. Thus a turbine.
surge tanks overcomes the strange weight in the
conductor when load on the turbine falls and goes about
as a repository amid increment of load on turbine.

ICMIEE-MC-160356- 3
Ƞv = , (2) 4. Components
The components of the system are as follows:
o Dynamo
in this project a little amount of water will be used. So o Shaft
the value of will be very low. We can neglect it. o Screw
So, Ƞv = 1, and hence, o Nut and bolt
o Tin sheet
Ƞ0=Ƞm× Ƞh (3) o Wooden basement
o LED light
Here, before striking the blade the velocity of water is V o Resistance
and after striking the blade velocity of water is u. o Diode
We can measure the head H.
Then we can write, 5. Design & Construction
5.1 Design of Turbine by Solid Works software
The output of power plant greatly depends on the
V= (4)
efficiency of turbine. Because the shaft of dynamo is
directly coupling with the turbine shaft. As much as the
Cv is the coefficient of velocity for the water tap with turbine rotate, the rotation of dynamo produce more
its value ranging from 0.97 to 0.98 .We can consider power which is the requirement. So, design of turbine is
this value is 0.98. shown below.
After striking the blade, a radial velocity will create.

So, u = , (5)

where D is the diameter of the wheel, which is constant.

Let us consider water will strike the blade at normal
direction. So force exerted by the jet,

F= (6)

, where w is the specific weight of water and a is the

cross section area of water tap from where water is
discharged.
So,
output = F × u (7) Fig.3. Solid Works design of Turbine blade.
, and 5.2 Total arrangement of the system
After designing the turbine, it is required to connect the
Input = (8) turbine shaft with the dynamo shaft. And then the
basement to hold the total system. The total system is
shown below.
Ƞh = = (9)

Again Ƞm= (10)

, where k is the factor which is less then unity.

As we consider Φ = 90 degree.

Finally we get, Ƞ0 = × (11)

, which is again equal to = (12)

Fig.4 Total arrangement of the project.
Here all frictional effect are neglected for the simplicity
5.3 Construction
of calculation [4].
o Sheet cutting process

ICMIEE-MC-160356- 4
 o Drilling process 7.Conclusion
o Welding process In the field of technology electric power is must needed.
o Grinding process Day by day the requirement of electric power increasing.
Hence, without power generation the whole
Sheet cutting: The blade of turbine was created by development process is impossible. From the data it is
cutting of stainless steel which is corrosion resistive. appeared that decrease the diameter of the jet the power
Two aluminum sheet was cut to hold the dynamo. and performance increase. It is very important system
for power development.
Drilling: The turbine wheel was drilled to make it light.
It was done by drilling machining. References:

Welding: The turbine blade was attached with the wheel [1] “Power Plant Engineering”, by G.R Nagpal,
by welding. The shaft of turbine was also connected by fifth edition ,
welding process. Finally the two dynamo was connected [2] “An Introduction To Hydropower Concept And
with the shaft of turbine Planning”, Canyon Hydro Publication.
[3] Published on the page of (U.S Department of
Grinding: The irregular surface on turbine due to energy publication).
welding was finished by grinding process. It’s make it [4] “Hydraulics And Fluid Mechanics Including
shiny and nice. Hydraulic Machines”, by Dr. P.N Modi & Dr.
S.M. Seth, new edition,
6. Result & Discussion [5] Celso Penche "Layman's guidebook on how to
Table 2 Table for experimental data develop a small hydro site", Published by the
Obser Cross Output Output Overall European Small Hydropower Association
vatio section of Voltage, Power, P Turbine (ESHA), Second edition, Belgium, June, 1998.
n No. jet, d V (watt) efficiency,
(m) (Volt) Ƞ0 Appendix

01 0.01 1.2 0.2 0.81% For observation no. 04

02 0.008 1.5 0.253 1.59% Water head H=17.4m, power P=0.568 watt

03 0.006 1.8 0.324 3.64% Area A= =0.000012566 sq m

04 0.004 2.5 0.568 14.38% Velocity V= =0.98 =18.1

m/s
The design of turbine blade for hydroelectric power Discharge Q =AV=0.00022745 cube m/s
generator was done by solid works software. The
efficiency of turbine is increase with the decrease of jet Efficiency Ƞ0 =14.38 %
dia. Because it increase the rotation of wheel and
corresponding electric power is also increase. The aim
of project was to design and constriction a mini-hydro
dynamic power generator. It was successfully done.
While designing the whole process the historical
background was studied. From where the concept of
power generation was came from was understood.
Similar process of power generation was also studied. A
proto type turbine blade was designed. The turbine
efficiency which was designed was calculated. The
output power get from this hydro dynamic generator
was calculated. It was observed that the overall
efficiency of turbine is not good. The reason behind this
that there use electric motor as a dynamo. Again the
dynamo is very small to produce huge energy. So output
power is little. But it was observed that with the
increase of rotation of turbine the power production was
also increased. The efficiency calculated is quite good.
It was thought that if this concept is applied in the hydro
power plant, it will be very efficient.

ICMIEE-MC-160356- 5

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