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Design and fabrication of Siphon Turbine

Technical Report · August 2023

DOI: 10.13140/RG.2.2.15679.28323

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 KATHMANDU UNIVERSITY
SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT REPORT ON

DESIGN AND FABRICATION OF SIPHON TURBINE

Manoj BK [026119-19]
Anjan Bhatta [026121-19]
Ashish Chhantyal [026127-19]
Rishav Devkota [026129-19]

JUNE, 2023
 Date:2023/06/05
To
The Project Supervisor
Department of Mechanical Engineering
Kathmandu University

SUBJECT: Cover Letter for Final Report

Dear Sir,
Submitted for your review is our project report entitled “DESIGN AND
FABRICATION OF SIPHON TURBINE.” The report is submitted as requirement
of course entitled Engineering Project MEEG 312. Within this document you will find
the basic introductions, objectives, methodology and expected outcome from the
proposed work (Listed in detail in the table of content section).
We look forward to your thorough review and future participation in this project, as well
as your approval.

Sincerely,
Aashish Chhantyal
Anjan Bhatta
Manoj BK
Rishav Devkota

ii
 PROJECT FINAL EVALUATION

DESIGN AND FABRICATION OF SIPHON TURBINE

By
Aashish Chhantyal, Anjan Bhatta, Manoj BK and Rishav Devkota

This is to certify that I have examined the above Project and have found that it is
complete and satisfactory in all respects, and that any and all revisions required by the
thesis examination committee have been made.

_________________________________
Er. Pawan Karki

Project coordinator

Department of Mechanical Engineering

_________________________________

Er.Uren Amatya

Project Supervisor

Department of Mechanical Engineering

iii
 ACKNOWLEDGEMENT

We are extremely privileged and indebted to the all the support, supervision, assistance
and guidelines, that we are receiving throughout the completion of the project.

Firstly, we owe our deep gratitude to Department of Mechanical Engineering,

Kathmandu University for providing this platform to do the project. Then with all due
respect, special thanks to our project supervisor, Er.Uren Amatya for providing the
necessary guidance and constant support, insightful feedback throughout the year We
would also like to thank our project coordinator, Er. Pawan Karki for giving us all
support and guidance, valuable insights, constructive criticism, and expert suggestions.
Their input and recommendations have significantly enriched this project and helped in
refining its scope and objectives.

Our special thanks go to Assistant Prof Pratisthit Lal Shrestha and Design Lab
played a pivotal role in the successful execution of this project. And to the countless
readers of this project report who are the most important critic and commentor. We
welcome constructive comments and suggestion which will help us to do better in
future. It is our radiant sentiment to place on record our kindest regards whoever were
directly and indirectly involved in the successful completion of this project.

iv
 ABSTRACT

This project intends to investigate design factors and develop the efficient Siphon-
turbine available. SOLIDWORKS was used to create a 3D model of the Siphon Based
Electricity Turbine. The 3D-designed pieces were also investigated in order to acquire
an idea for future production. This study also highlights the significance of the Siphon
turbine due to its super low head power generation and low environmental impact. 3D
Printing has been used for creating runner model. A Siphon-based ultra-low head
electricity motor seeks to generate enough electricity locally from a medium current of
water flow. It is designed to work with a low head of 2.5m to 15m in a flowing river.
The purpose of this study is to develop and construct a Siphon-based electricity turbine.
In this project, the main advantage of using a Siphon-based water turbine is that it gives
us a choice to use either Kaplan or Propeller turbine according to the available head. In
this project, Kaplan water turbine is used as it can work more efficiently at low water
head and high flow rates as compared to other turbines.

v
TABLE OF CONTENTS

ACKNOWLEDGEMENT ............................................................................................. iv

ABSTRACT ................................................................................................................... v

TABLE OF CONTENTS .............................................................................................. vi

List of figures ..............................................................................................................viii

List of Tables ................................................................................................................. ix

List of Abbreviations ...................................................................................................... x

List of Symbols.............................................................................................................. xi

CHAPTER 1 INTRODUCTION .................................................................................... 1

1.1 Background........................................................................................................... 1

1.2 Literature Review ................................................................................................. 3

1.3 Objectives ............................................................................................................. 5

1.4 Significance .......................................................................................................... 6

1.5 Limitations ............................................................................................................ 6

CHAPTER 2 METHODOLOGY ................................................................................... 7

2.1 Work Plan ............................................................................................................. 7

2.2 Theoretical Framework ........................................................................................ 8

2.3 Theoretical Calculation ........................................................................................ 9

2.4 Conceptual Design.............................................................................................. 14

2.5 Working Principle .............................................................................................. 16

2.6 Study Design ...................................................................................................... 17

2.7 3D Models and Components .............................................................................. 17

2.8 Fabrication Process ............................................................................................. 24

2.8.1 Preparation of Runner.................................................................................. 24

vi
 2.8.2 Preparation of Shaft for coupling ................................................................ 25

2.8.3 Fabrication of frame .................................................................................... 25

2.8.4 Motor Holder ............................................................................................... 26

2.9 Machine used during fabrication ........................................................................ 26

2.9.1 Hand Grinder ............................................................................................... 26

2.9.2 Tiertime Printer ........................................................................................... 27

2.9.3 Drill.............................................................................................................. 27

2.10 Assembly of Components................................................................................. 27

CHAPTER 3 EXPENDITURE .................................................................................... 29

CHAPTER 4 RESULTS............................................................................................... 30

CHAPTER 5 CONCLUSION ...................................................................................... 31

REFERENCES ............................................................................................................. 32

APPENDIX .................................................................................................................. 34

vii
 LIST OF FIGURES

Figure 1 Two Siphon turbines set at Vallorbe ................................................................ 2

Figure 2 Siphon Turbine installed in Ukraine ................................................................ 2
Figure 3 Project Flowchart ............................................................................................. 7
Figure 4 Velocity Triangle ........................................................................................... 13
Figure 5 Conceptual Design of Siphon Turbine System .............................................. 14
Figure 6 Hand Drawing of Siphon System................................................................... 15
Figure 7 Five Blades Runner With 91.7mm Diameter ................................................. 15
Figure 8 Turbine Runner .............................................................................................. 18
Figure 9 3D Printed Runner ......................................................................................... 19
Figure 10 Shaft Cad Model .......................................................................................... 19
Figure 11 Threaded Galvanized steel rod ..................................................................... 20
Figure 12 DC motor 12V .............................................................................................. 20
Figure 13 DC motor CAD model ................................................................................. 21
Figure 14 Muff coupling .............................................................................................. 21
Figure 15 CAD Muff Coupling for shafts ................................................................... 22
Figure 16 Nut and Bolt ................................................................................................. 22
Figure 17 Outer frame of siphon system ...................................................................... 23
Figure 18 Front View of 3D model in printer .............................................................. 24
Figure 19 Top view of 3D model in printer ................................................................. 24
Figure 20 One sided grinded at 8mm ........................................................................... 25
Figure 21 Siphon structure to be framed ...................................................................... 25
Figure 22 Heating of PVC pipe for motor holder......................................................... 26
Figure 23 Hand grinding .............................................................................................. 26
Figure 24 Tiertime printer in design lab ....................................................................... 27
Figure 25 Final assembled siphon structure ................................................................. 27
Figure 27 Assembled siphon system ............................................................................ 28
Figure 26 Assembly of all parts.................................................................................... 28

viii
 LIST OF TABLES

Table 1: Budget expenditure ........................................................................................ 29

ix
 LIST OF ABBREVIATIONS

DC Direct Current
KW Kilowatt
PLA Polyactic Acid
PVC Polyvinyl Chloride
SHP Small Hydro Power

x
 LIST OF SYMBOLS

m Meters [m]
D Diameter [mm]
Q Flow Rate [m3/s]
M Mass [kg]
η Efficiency
ρ Density of water [kg/m3]
g Acceleration due to gravity [m/s2]
𝜏 Shear Stress [MN/mm2]
T Torque [N.mm]
P Power [watt]

xi
 CHAPTER 1 INTRODUCTION

1.1 Background
The electricity demand for growing population is getting high day by days and
hydropower plants tend to fulfill this demand in a suitable way. The production of
electricity from water is necessary to build large dams which have an effect to the people
in the area. Hydropower contributes only 3% of global energy consumption which is
only a fraction of its potential [1]. Hydroelectric energy is safer and more cost-effective
form of energy. Hydroelectric power generally involves the use of falling water to drive
turbines which in turn drive motors to generate electricity. While conventional
hydroelectric power generation has typically depended on the availability of running
water, many prior art systems have attempted to employ static water as a source to
generate hydroelectric power. The principle behind siphon turbines was described over
35 years ago, with a US patent for a “Hydraulic Turbine System with Siphon Action”
being filed in 1980 and granted in 1982 [2].
A siphon turbine has the advantage in small-scale hydropower that it can be retrofitted
in existing structures. For example, suitable places are non-powered dams, irrigation
canals, water diversion structures, water distribution systems, water or wastewater
treatment plants and others. The siphon conveys the water from the upper reservoir over
the dam into the lower reservoir.
It is only during the last two decades that there is a renewed interest in the development
of small hydro power (SHP) projects mainly due to its benefits particularly concerning
environment and ability to produce power in remote areas. So, this study presents a new
concept of hydroelectric power, using the standing water to resource by designed the
siphon to the small water resources of water under vacuum tanks as pumps. The
siphoning action relies on the gravitational force and the cohesion that prevents the
columns of liquid from separating under their own weight.

1
 Figure 1 Two Siphon turbines set at Vallorbe [3]

The above-mentioned figure 1 describes two Siphon turbines set at Vallorbe, designed
with MHyLab’s hydraulic profile having the discharge of 2.5 m3/s per machine and with
head of 2.1 m. The total electrical output of the turbine is 85 kW having external runner
diameter of 1.25 m [3].

Figure 2 Siphon Turbine installed in Ukraine [12]

Figure 2 shows the siphon turbine installed in Ukraine with capacity of 100kW. A
siphon also works in a vacuum. There produces flowing water and drives the hydro
turbine to generates the electricity. Then, analysis is made which affect to
hydroelectricity power generation for increase the efficiency of water’s useful as design
of hydro turbine and the angles of outlet pipe [1]. These turbines have propeller blades,
similar to the blades found in Kaplan turbines. The blades are connected to a turbine
shaft that turns a motor. The turbine only starts operating after 30–60 s, during which

2
acts as an electromotor that pumps water into the siphon until it is primed, after which
it starts functioning as a motor.

1.2 Literature Review

A siphon is an inverted U-tube that is powered by the fall of the liquid as it flows down
the tube under the pull of gravity and allows liquid to flow uphill above the surface of
the reservoir (a tank with the greater height of water) without the use of pumps. The
liquid is discharged at a level lower than the surface of the reservoir. The idea behind
this invention is to create a siphon principle that works with hydroelectric power and
allows drops to act as motors without the use of any additional energy sources or
dependence on the natural world. Siphon pumps are an energy-based type of pump used
to move water from a high point to a low point elevation. Number of studies regarding
the Siphon Pump and generation of electricity extraction have been done by the
researchers.

Improving the siphon turbine's design and adjusting the outlet pipe's angles to the proper
direction, the siphon prototype that is connected to an electric motor can produce more
electricity. It could be concluded that the parameters which affect to hydroelectricity
power generation are design of hydro turbine and the angles of outlet pipe. The most
suitable turbine is the stainless turbine with 45 angle degree of outlet pipe [1].

The study can conclude that the free energy pump cannot deliver water from the lower
area to supply the higher area. However, the small difference of the elevation between
the water resource and the outlet of 5 cm could operate the pump continuously [4]. The
siphon pump prototype will increase the discharge rate by increasing the height
difference and increasing the diameter of the outlet pipe.

With the driving head of 1m and an aerator height of 2 m, the system achieved a
maximum void ratio of 0.116 and a power output of 20 Watts, with an efficiency of
10%, about 50% less than was predicted [5]. The void ratio and the power output are
were 0.1165 void fraction, and 22 watts power output for a driving head of 1 m and an

3
aerator head of about 2 m in 150 mm pipe diameter [5]. Water flow must be as high as
possible in order to maximize air flow. This produces the highest power output. At the
same time, it is necessary to reduce the void as much as possible in order to create the
highest suction pressure. The key for achieving this will be in the design of the aerator
height.

The design, setup, and operation of a prototype underwater turbine motor with a
gravitational vortex and siphon was presented to yield a suitable, small, and inexpensive
Siphon prototype with a power range of 2 to 10 kW and a head of 0.8 to 3 m with
efficiency to be 37% [6].

A laboratory scale experiment with a very small diameter pipe of 19 mm and 0.43 m
hydraulic head was done [7]. Air was blown rather than induced into the down pipe
achieving maximum efficiency of 45% concluding that flow rate is directly proportional
to the hydraulic head and the cross-sectional area of the down pipe.

Syfogen was created by combining a siphon with a venturi at its highest point at
Borrowash on the Derwent River. Theoretical calculation showed that the Syfogen
would achieve an efficiency of 50%. The prototype was tested in March 1992 and
reached an efficiency of 25%. The prototype was left operating until July 1993 [8]. This
showed that the system was reliable and easy to operate. A second experiment was
carried out in February 1994 after a significant review of the design. With 2.3 m of head,
it produced 22 kW of energy, achieving 30% efficiency [8].

The siphon turbine concept was developed by MHyLab for outputs greater than 40 kW
and is particularly suited for ultra-low head sites (1.5–3.5 m) [3]. The concept enables
the development of standardized machines in order to combine low investment and
optimal use of the water resource.

4
Three siphon turbines in parallel were selected for the installation, as they could be
easily retrofitted to the existing structure and provided a more cost-efficient alternative
than other options (like a propeller-type turbine) and can be developed in phases in case
of installation cost in South Africa. The installed capacity per unit would be 6.7 kW,
with a net head of 3.6 m and discharge of 0.37 m3/s per unit [9]. The use of parallel units
would facilitate operation during low and high flow periods.

On a straightforward weir-wall, the turbine is mounted directly. The vacuum is broken

down by the electro-valve at the highest point of the turbine inlet, which allows it to be
started up by the vacuum pump and shut down by it. Thus, this method always involves
a straightforward and secure stopping of the turbine without the use of any valves, which
saves money and space.
The condition for the Siphon system needs to be following:
• The cross section of a siphon penstock does not change along its entire length
• The pressure on the surface of the pools is equal to the atmospheric pressure.
• The siphon penstock is completely rigid and cannot deform in any way.
• Water, a viscous uncompressible fluid, serves as the working medium.

The siphon system uses a diameter of relatively or more 100 mm according to the
research papers excluding some of the projects which use much less than 100 mm
smaller diameters [8].

1.3 Objectives

• To design and fabricate the low head Siphon turbine energy generation system.
• To study the working of siphon mechanism.

5
1.4 Significance

• Siphon Turbine can convert the potential energy of a river with a relatively low
head and low flows into electricity.
• Siphon Turbine can generate hydroelectricity power from low velocity flowing
water.
• It doesn’t require high flowing velocity of water.
• Siphon Turbine is environmentally advantageous and economically feasible.

1.5 Limitations
• Study of wear and effect of cavitation will not be done.
• Study of the effect of change in height and no of blades on turbine efficiency is
not done.
• Horizontal length of the shaft area shouldn’t be larger.
• Lower the height from ground level, lower will be the efficiency.
• High weight of turbine and rotating materials could affect hardly.
• Extreme limitation on migratory fish undergoing turbine passage.

6
 CHAPTER 2 METHODOLOGY

2.1 Work Plan

The mentioned Figure 3 shows the flowchart of work plan for the project completion
process.
START

TOPIC SELECTION

LITERATURE REVIEW

MATHEMATICAL
CALCULATION

NO
DESIGN

YES

MATERIAL SELECTION

FABRICATION

NO
TESTING

YES
FINAL DEMONSTRATION

END

Figure 3 Project Flowchart

7
Above mentioned Figure 3 shows the flow chart on the work plan throughout our
project. First, we select the topic for project and we study further in this topic. Then we
move towards its design and necessary collection of data. After collection of data, we
do some theoretical calculation. After theoretical calculation it is followed by its design
at first, we design a cad model and then we will fabricate the materials. If the design of
the materials is according to the calculation, then we move forward otherwise not. Then
the testing of device is done regarding power. If testing is okay, then we will move
forward. Testing includes the power obtained and the assumed rpm of motor. And we
move towards further demonstration and final presentation.

2.2 Theoretical Framework

Siphon water turbines are the type of turbines that tends to be used in small hydroelectric
sites. Siphon water turbine works on converting rotational energy to electrical energy
during a flow of water from a higher elevation to a lower elevation due to pressure
difference, cohesive, height difference which can be used in rural areas for small
household activities. The siphon turbine and axial type propeller turbine motor are the
examples of modular reaction turbines. The developing siphon water turbine will be
made from PVC, Iron, dc motor. The component will be assembled which works on
Siphon Principle which converts rotating turbine into electrical energy and finally
electricity is generated with help of dc motor. The Siphon Turbine will be assembled
with the combination of the following materials.
i. DC Motor
ii. Iron
iii. Wire
iv. Runner Blades
v. Nut bolt
vi. PVC Pipe
The manufacturing material of runner blades is plastic (UP-Fila) to minimize the size
and cost of the turbine which automatically reduces its weight and becomes portable.
During the development of a Siphon water turbine, a tee connector is assembled where

8
a motor is connected with the help of a supporter that is tightened by nut and bolts and
thus motor is joined with rotating shaft and blade which causes a voltage to be produce
which is measured by using a multimeter that is connected to a wire of a motor. A wing
bolt is connected to the end of a shaft which is connected to a motor which helps in
rotating a motor while shaft is rotating. After that, connect a long pipe to a degree tee
connector, through which water flows smoothly a suction is created on the tube, which
causes a pressure difference on the tube, causing flows through a pipe's inlet to outlet
valve. The pipe through which a liquid flow should be smooth because rough surfaces
cause energy loss.

2.3 Theoretical Calculation

As the liquid flows through a tube, it rotates the turbine and flows through an outlet
of a tube with a certain velocity to calculate velocity, we use the Bernoulli equation
as it states that the sum of the pressure, velocity, and elevation heads is constant.
The energy line is this sum or the “total head line” above a horizontal datum.
𝑃1 𝑣2 𝑃 𝑣2
+ 2𝑔1 + ℎ1 = 𝜌𝑔2 + 2𝑔2 + ℎ2 (2.1)
𝜌𝑔

Where, P1 and P2 = pressure at inlet and outlet sections,

V1 and V2 = average velocities at the sections,
h1 and h2 = vertical distance
g = acceleration due to gravity
According to the study, atmospheric pressure at both points and inlet velocity being

negligible we can conclude that the velocity at the outlet portion depends on the

gravity and the height difference which can be written as below:

𝑉 = √2𝑔𝐻 (2.2)

Where, H= height difference between two end points.

9
According to the above equation, the velocity of a fluid in a Siphon turbine is generally

determined by the acceleration and height difference between two points. To increase

the high speed of a turbine, the height of the two ends of the tubes should be increased,

resulting in a high rotation of the motor shaft and higher voltage production.

And to begin with the designing part of the same, parameters like power, flow rate, and

runner diameter first have to be determined. Depending upon the site selected, the

calculations of these parameters are done in this section.

Assumptions;

Net head(H)= 3m, initial assumption

Assuming minimum head of Kaplan turbine i.e., 3m as our project aims for low head

and high discharge.

According to the studies of the papers, it is concluded that the diameter was taken

usually within 100mm for siphon pipe in small scale.

Availability of PVC pipe in market made to choose 4inch diameter pipe (10.4 cm).

So, diameter of pipe is 10 cm.

Overall efficiency (𝜂𝑡 )= 0.8 globally assumed efficiency

Density of water (ρ)= 1000kg/m3

Acceleration due to gravity(g)= 9.81 m/s2

h=Ht /H,

Here, (H-Ht) is the assumed inlet suction pipe length which ranges between 5 to 10

times the pipe diameter [10].

10
Ht=2.5 m (assumption)

Losses(k)= 0.05 for head loss at entrance

0.35 for 45° elbow

Then,

Velocity of water in the siphon system with some losses,

(1−ℎ)×(2−𝜂𝑡 )
𝑉 = √2 × 𝑔 × 𝐻 × (2.3)
1+𝑘

V= 2.64 m/s

𝑄 =𝐴×𝑉 (2.4)

𝑑2
=𝜋× ×𝑉
4

0.1042
=𝜋× × 2.64
4

=0.0224 m3/s

In reality there will be some losses in the system. If it is estimated 30% losses in total,

the siphon velocity would be 2.64 m/s or Q = 15.68 liter/s.

i.e., 0.01568 m3/s

Now, For Theoretical Power,

𝑃 = 𝜌×𝑔×𝑄×𝐻×𝜂 (2.5)

P = 369.16 Watt

𝑁√𝑃
Specific Speed, 𝑁𝑠 = 5 (2.6)
𝐻4

Ns= 184.64

The number of blades for the siphon turbine was determined by specific speed i.e., 5

taken as reference [11].

11
 2𝜋𝑁𝑇
𝑃= (2.7)
60

From this we calculate torque,

T= 2937.91 N.mm

Again, having the relation of torque with shear stress, the diameter of the shaft is

calculated as below:

Shear stress for galvanized steel 𝜏 = 100 𝑀𝑁/𝑚𝑚2

Factor of safety(f)= 3.5 in case for shaft resistance and shocks

3 16𝑇×𝑓
Diameter of shaft, 𝑑 = √ (2.8)
𝜋×𝜏

𝑑 = 8.05 𝑚𝑚

According to the standard shaft diameter we choose 10mm for the project.

For Runner diameter

𝑉𝑚1 = 0.12 + 0.18 °Ω (2.9)

2𝜋×𝑁 𝑄
°Ω= ×√ (2.10)
√2×𝑔×𝐻 √2×𝑔×𝐻

So, 𝑉𝑚1 =8.11

4×𝑄
𝐷𝑟𝑢𝑛𝑛𝑒𝑟 = √𝜋×𝑉 (2.11)
𝑚1

𝐷𝑟𝑢𝑛𝑛𝑒𝑟 = 49.62𝑚𝑚

The obtained diameter needs to be coincided with the diameter of the pipe to obtain the

optimum efficiency. So, the diameter of the runner with respect to diameter of pipe is

approx. 104 mm. After some clearance for passage of water, the diameter of runner is

made to be 92mm.

For hub diameter,

12
𝐻𝑢𝑏𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0.35 × 92𝑚𝑚=32mm

0.75×3.14×91.7
Chord length,𝐶 = =48.7 mm
5

Calculation of Inlet and Outlet Blade Angle

Figure 4 Velocity Triangle

𝑄 = 𝐴 × 𝑉𝑓1

(0.0922 − 0.0322 )
0.01568 = 𝜋 × × 𝑉𝑓1
4

𝑉𝑓1 = 2.68 𝑚/𝑠

0.092 × 1200
𝑢1 = 𝜋 ×
60

𝑢1 = 5.71 𝑚/𝑠

We know, 𝜂 = 0.8

𝑢1 × 𝑉𝑢1
= 0.8
𝑔×𝐻

𝑉𝑢1 = 3.65 𝑚/𝑠

For inlet angle,

𝑉𝑓1
tan 𝛽1 = 𝑢 (2.12)
1 −𝑉𝑢1

𝛽1 = 52.2°

13
For outlet angle,
𝑉𝑓2
tan 𝛽2 = (2.13)
𝑢2

𝛽2 = 30.54°

2.4 Conceptual Design

Figure 5 depicts a conceptual design of a Siphon Turbine in which the low flowing
liquid is passed through a trash rack where it separates the rocks, aquatic animals, and
so on from the liquid where a separated liquid is distributed, by a fluid distributed where
the flowing fluid strikes a turbine shaft axial causing a reaction on a turbine.

Figure 5 Conceptual Design of Siphon Turbine System [12]

This reaction force causes the rotor to spin quickly. The turbine shaft is rotated by the
resulting high-speed water. This shaft continues to rotate the motor/motor coil,
producing electricity. The flowing liquid is then forwarded through an electromagnetic
valve, which regulates the fluid and the fluid characteristics they control. The flowing
liquid is then passed through a draft tube, which is fitted at the exit of the tube's runner
and used to utilize the kinetic energy available with water at the exit of the runner. This
draft tube at the turbine's end raises the pressure of the exiting fluid while decreasing its
velocity.

14
Figure 6 shows the hand drawing of the siphon turbine that helps on conceptualizing the
proposed project. Here the below figure composed with the height of 3m (approx.) as
per the taken assumption.

Figure 6 Hand Drawing of Siphon System

Figure 7 depicts a runner blade with 91.7 mm diameter and 5 blades. The figure details
about the 3D printed CAD model basic fan design which has been used as a turbine to
rotate a motor when water is passed through it.

Figure 7 Five Blades Runner With 91.7mm Diameter

15
2.5 Working Principle
The Siphon is an inverted U shape pipe having two ends one is long end other is short
end where the higher end is submerged into the container at lower elevation. The liquid
flows continuously from a higher elevation to a lower elevation without any external
force or power due to pressure difference, cohesive force and gravitational potential
energy. During the flow of liquid from short end the turbine is inserted in PVC pipe
where it strikes the flowing liquid and rotates the turbine. As the turbine is connected to
motor where it finally converts rotating energy to electrical energy. First of all, water
should be poured from the top portion in order to create vacuum inside the pipe which
lets to pull water from top to the bottom part. Atmospheric pressure at the inlet portion
is more than at the other point. Water gets through the inlet pipe having the elevation of
more than 3m (assumption) from the ground level. That means having the more
elevation/height increases the efficiency rate. Fan is connected with motor. When water
gets through the inlet pipe hits the fan making it to rotate and the motor too. More the
revolutions we have, more the voltage which means less transmission loss. In the
working of a Siphon turbine, the reaction force is generated by the moving fluid above
the impeller blades the reaction forces generated in the impeller blade causes impellers
to rotate. This reaction force causes the rotor to rotate at high speed. The resulted high-
speed water rotates the turbine shaft. This shaft further rotates the motor/motor coil and
produces electricity. Velocity at the outlet portion depends on the gravity and height
difference. We can adjust the height difference in order to get the higher efficiency and
the best outcome.

16
2.6 Study Design
Since the velocity of a turbine is dependent on height difference and gravity so it should
be considered before installing a turbine, the area of water inlet should be reduced as its
velocity has inverse relation similarly an inlet pipe should be at 45° which helps in
increasing the velocity of liquid resulting in high efficiency as the rotating speed of a
blade also increases. Similarly, the pipe through which the liquid flows should be
smooth because rough surfaces reduce some of the energy present in water. In order to
eliminate such loss, smooth pipe should be considered when designing the turbine.
When water flows through an inlet pipe, it strikes a blade which can withstand the force
and torque produce by striking water and shaft is connected to a rotating blade which
has a capacity to bear the torque produced by water when it strikes a rotating blade. The
number and configuration of the blades are critical because they affect the speed and
efficiency of the turbine. Inadequate performance is caused by having too few blades.
A large number of blades increases weight and production costs. The correct number of
blades is critical for fitting the motor/motor performance curve and optimizing overall
turbine performance and efficiency. As uniformity of the flow and torque is the
effect of increasing the number of turbine blades. Likewise, the rotating fan should be
tightly tightened because a loosely tightened fan causes more vibration on the shaft,
which might cause shaft damage and reduce overall turbine performance.

2.7 3D Models and Components

The initial estimated 3D modeling of the components design is done by using
SOLIDWORKS software with proper dimensions. Following are the components
included in the system.

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• Blade Runner: The runner blades in the cranium turbine are the heart of the
component, as they are the revolving section that aids in the creation of
energy. The shaft is linked to the motor and shaft. This turbine and runner
have a huge boss with its blades affixed, and the runner and blades are
adjustable to an ideal angle of attack for maximum power generation. The
Kaplan turbine has a twist running the length of it. Since it is a reaction
turbine so the reaction force of leaving water is used to turn the runner of the
Kaplan turbine, As the water flows through the twisted blades a lift force is

Figure 8 Turbine Runner

generated in the opposite direction of the leaving water and that lift force
causes the blades to rotate. Figure 8 resembles the CAD model of the runner
with 91.7mm diameter. It consists of 32mm hub diameter and 30mm blades
length each.

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 The runner blade is printed in design lab with UP-fila material. The diameter
of the runner is 91.7 mm having hub diameter as 32mm. The length of the
hub is around 40mm. Similarly, the thickness of the blade is around 4mm.
Weight is approximately 97g. Figure 9 shows the 3D printed runner.

Figure 9 3D Printed Runner

• Shaft
A shaft used in the Siphon turbine is to hold the runner blade and the motor.
Kinetic energy is converted into mechanical energy by blades and rotors and
then transferred to a motor via shaft. Figure 10 shows the 47 cm galvanized
steel shaft length.

Figure 10 Shaft Cad Model

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 The shaft used is 10 mm diameter galvanized steel rod. It is low weight and
threaded rod is used for easier process. The length of the shaft used is 47 cm.
Figure 11 shows the threaded galvanized steel rod used in this project.

Figure 11 Threaded Galvanized steel rod

• DC motor
Siphon turbine are usually equipped with synchronous dc motor operating at
variable angular speeds based on permanent magnets. It is a design solution
which can contribute to meeting the requirements of efficient operation.
Figure 12 resembles about the 12-volt dc motor.

Figure 12 DC motor 12V

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 The dimensions and specs of the motor are:
Specifications of Motor
Name: Dynamo 12v
Phase: Direct Current
Power: Electric Power
Motor Voltage: 12V
Speed: 1000-2000 RPM
Figure 13 shows the CAD model of dc motor.

Figure 13 DC motor CAD model

• Coupling
Muff coupling is the simplest type of rigid coupling used to connect two
shafts together. It consists of a hollow cylinder with the same inner diameter
as the shaft. Figure 14 shows the 8mm by 5mm coupling.

Figure 14 Muff coupling

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 Coupling has been used to couple threaded shaft and shaft of dc motor. 8mm
by 5mm coupler has been used where 8mm is shaft diameter and 5mm is dc
motor diameter. Figure 15 resembles the CAD muff coupling.

Figure 15 CAD Muff Coupling for shafts

• Nut and Bolts

A bolt is a type of fastener, usually made from metal, which commonly
comprises a head at one end, a chamfer at the other, and a shaft characterized
by an external helical ridge known as a 'thread'. Bolts are typically used to
hold materials or objects together, or to position objects. They have been
used for the support purpose only in this project. Mainly 10mm and 5mm
diameter bolts were used. Figure 16 shows about the nut and bolts.

Figure 16 Nut and Bolt

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• Frame Body
A frame is the main supporting structure of turbine to which all the other
components is attached. It is a rigid structure that protects the turbine as a
whole, including the blades and other components. The inlet length is
estimated to be 40 cm. The length of horizontal pipe support including the
y-shape is 70 cm. Also, the length from top of the cap to the outlet of the
pipe is 3m. Figure 17 resembles about the outer frame or the structure for the
siphon system.

Figure 17 Outer frame of siphon system

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2.8 Fabrication Process

2.8.1 Preparation of Runner

Our approach was to print the 3D printed runner under the supervision of Design Lab
of Kathmandu University. The material to be printed was runner along with hub and
five blades. For the printing process, UP-fila PLA plastic was used recommended by
the instructor. The tier time printer was set with the layer thickness of 0.3mm and infill
with 99%. Figure 18 and figure 19 depicts about the front and top view of the runner
being 3D printed.

Figure 18 Front View of 3D model in printer

Figure 19 Top view of 3D model in printer

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2.8.2 Preparation of Shaft for coupling
Initially, shaft was 10mm and it was impossible to make coupling in 8mm by 5mm
coupler. So, the shaft was grinded with hand grinder as it was impossible in lathe
machine being its length more. Figure 20 sows the grinded shaft at one end at 8mm.

Figure 20 One sided grinded at 8mm

2.8.3 Fabrication of frame

The frame structure is likely to be inverted U-shaped. PVC pipe was used for the body
frame. T-connector and Y-connector were used for giving shape. A pivot point is made
by drilling the PVC pipe along 120° in three axes. Figure 21 depicts the PVC pipe made
ready for final structure.

Figure 21 Siphon structure to be framed

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2.8.4 Motor Holder
Two wooden rods were taken and drilled in Y- shape connector for holding dc motor
along the shaft where coupling is attached. And the PVC pipe was heated to make the
holding shape for the motor. Figure 22 shows the way of changing shape of PVC pipe
by heating.

Figure 22 Heating of PVC pipe for motor holder

2.9 Machine used during fabrication

2.9.1 Hand Grinder

An angle grinder is a handheld power tool that can be used for a variety of metal
fabrication jobs that include cutting, grinding, deburring, finishing and polishing. Hand
grinder was used to smooth out the shaft parts and cut the extended metal pieces while
frame construction. Figure 23 shows the grinding process.

Figure 23 Hand grinding

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2.9.2 Tiertime Printer
Tiertime 3D printer was used to print the 3D model during the fabrication process.
Nearly 97g was used during the printing process with the 2.6 hours printing time. Figure
24 shows the tiertime printer in design lab.

Figure 24 Tiertime printer in design lab

2.9.3 Drill
Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-section
in solid materials. The drill bit is usually a rotary cutting tool, often multi-point. Drill
was used to make holes in Y-shape for pivot point and for motor holder.

2.10 Assembly of Components

The final assembled model using all the parts shown below. Figure 25 shows the final
assembly of the Siphon system along with all the components.

Figure 25 Final assembled siphon structure

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The final assembly design of a Siphon turbine is shown in figure above. In the assembly
at first the turbine is inserted in Y shaped pipe and the shaft connected to a turbine is
joined to a motor where the rotational energy produces by a fluid is converted to
electricity through motor which is measured using a multimeter. The outlet fluid flowing
through a pipe is then flow through Tee pipe. Figure 26 and Figure 27 resembles about
the final fabricated assembly of all the components.

Figure 27 Assembly of all parts

Figure 26 Assembled siphon system

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 CHAPTER 3 EXPENDITURE

Table 2 shows the spent budget of the project. As our budget plan, we spent our budget’s
27.91% to buy 3D printing UP-fila, 27.91% to buy PVC pipe, 9.76% to buy a PVC Cap,
6.97% to buy a Threaded Galvanized Shaft, 6.28% to buy DC Motor, 6.28% to buy PVC
tee connector, 6.28% to buy y connector ,4.18% to buy muff coupling, 2.79 % to buy a
Miscellaneous material, 1.25% to buy Nuts and Bolts and 0.34% to buy Screw. Mostly
the 3D printing UP-fila and PVC pipe takes our budget which is 27.91 % of total budget.
Finally, we got the total expenditure budget of Rs 7165.

Table 1: Budget expenditure

Components Specification Quantity Rate/pieces Cost

DC Motor 12V 1 Rs 450 Rs 450
Muff Coupling 5mm by 8mm 1 Rs 300 Rs 300
Threaded Steel (10mm diameter, 1 Rs 500 Rs 500
Galvanized Shaft 40cm length)
3D printing UP- Plastic (250 gram) 1 Rs 2000 Rs 2000
fila
PVC Tee Single sided (110mm) 1 Rs 450 Rs 450
connector
PVC pipe 4m length 1 Rs 2000 Rs 2000
PVC Y connector 110mm and 45 degrees 1 Rs 450 Rs 450
Screw Stainless (3mm) 10 Rs 2.5 RS 25
Nuts and Bolts Stainless (5mm) 4 Rs 15 Rs 60
Stainless (10mm) 2 Rs 15 Rs 30
PVC Cap 4 inches 2 Rs 350 Rs 700
Miscellaneous Tape, Glue stick etc. Rs 200 Rs 200
materials
Total:7165

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 CHAPTER 4 RESULTS

The specifications and requirements for the design were established. The theoretical
framework's final section was successfully completed. Various sources were gathered
and evaluated. Different parts were designed. Calculations were done to determine the
various parameters for the fabrication of Siphon Turbine. Necessary tinkering was done
on the design aspect to make the turbine effective.

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 CHAPTER 5 CONCLUSION

During the study, design, and fabrication of the turbine, various information regarding
the performance, design attributes, fabrication approach, and mathematical calculations
of the siphon turbine was gathered. A small prototype siphon turbine was successfully
constructed using locally accessible materials and techniques. Up to 5 Watts of
electricity can be produced as per the expectation by the manufactured Siphon Turbine
and easily lighting a lightbulb. The portable turbine only weighs about 8 kg
approximately. To find the most effective process for designing and making a Siphon
turbine, more research is required. Leaks and overflows of water are also significant
problems that affect the production of electricity, so they must be reduced.

31
 REFERENCES

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power production," ” International Journal of Mechanical Engineering and
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[13] J. J. M. e. al, "Characterization of a siphon turbine to accelerate low head
hydropower deployment," J Clean Prod, , Feb. 2019,.
[14] M. J. F. a. M. B. Widden, "The exploitation of low-head hydropower by pressure
interchange with air, using siphons," Proceedings of the Institution of Mechanical
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Plants," 2015.

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 APPENDIX

The CAD drawings of part embedded in our siphon system is shown below.
• Final Assembly of all parts
• Runner
• Shaft
• Coupling
• Motor

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35
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