2016 International Electronics Symposium (IES)

Design and Build of Hydropower Testing System

in Scale of Laboratory
Setyo Nugroho, Fifi Hesty Sholihah, Nur Fadlilah Husnandanti,
Muhammad Rozaki , Ardanto Kusuma Nurindiyono
Power Plant Engineering of Politeknik Elektronika Negeri Surabaya (PENS)
Surabaya, Indonesia
[email protected], [email protected], [email protected],
[email protected], [email protected]

Abstract — This hydropower testing system module is From the availability, hydropower is still use for
adopted from environmental condition into a laboratory about 6% or equals to 3,529 MW. Until September
scale. It is intended to be easily analyzed the variables that 2014 operational power plant PLN and IPP in Indonesia
can increase the mechanical power of water turbine. The reach 43,457 MW, which are 33,499 MW in Java and
objects of this research are pelton turbine and francis Bali and 9,958 MW in Sumatra and East Indonesia.
turbine. This module is able to vary five variables including Cause of declined some projects in power plant it is
flow rate, nozzle distance, nozzle velocity, number of nozzle important to students at university to empower
and angle of attack of the nozzle. In piping system is electricity development. To increase knowledge and
analyzed major and minor head loss. In pelton turbine the
research that related to hydropower then researcher
mostly affected by varying number of nozzle from 6.27 watts
to 11.5 watts, increased an average of 1.8 times. Mechanical
make hydropower testing system in scale of laboratory
power of francis turbine is affected by flow rate, by as research center of hydropower in campus and to
increasing flow rate in range of 0.2 m3/h the mechanical fulfill electricity needs in future. Kind of turbines that
power also increase in the amount of 0,1 watt. Highest head analyze are impulse and reaction turbine. Pelton as
loss reached 5.3 meters, it occurs in francis turbine. The impulse turbine and francis as reaction turbine. The
high value causes from many types of fitting, pipe length, reason why researchers choose these types of turbines is
and minor loss coefficient. At the same flow rate 0.00347 about the suitable head of waterfall in Indonesia about
m3/s pelton turbine generate power up to 5.5 watts and 80-150 meters. In this research is model the geographic
francis turbine 1.3 watts. The efficiency of hydropower condition into laboratory scale. Parameters that will be
testing system that compares mechanical power and pump analyzed are the effect of debit variation, testing
hydraulic power is 8%. Overall the power that can be system, head loss and system efficiency. By analyze it,
generated by turbines is affected by total head that working researcher can modify the variables that increase the
on the system. turbine performance.
Keywords: turbine, head loss, mechanical power, testing II. LITERATURE REVIEW
system.
A. Water Turbine
I. INTRODUCTION Water turbine is a turbo machinery take the kinetic
Up to 2013, there are 20% areas in Indonesia that energy of a current of water. Water turbine developed at
haven’t got electricity. The number of electricity ratio the beginning of the 19th century and widely used for
is decrease from 35% in 2009 become 29.6% at the exertion industry before a network of electricity .Now
beginning of 2014. In order to complete the demand it water turbine used to power plant. Water turbine is
is important to optimize renewable energy uses. One come as resources of clean energy and among. Water
resource that abundant is water. Spread from turbine coupled with generator uses transmission/the
Indonesian Energy Outlook 2013, PUSDATIN gear box of order to be able to produce electric energy.
KESDM said that availability of water reach 75,000 To define type of turbine is come from specific
MW. By develop renewable energy we got many speed (ns). Specific speed is the main criterion used to
advantages: reduces CO2, increase energy endurance, fit condition water resources with a kind of a turbine
value from renewable resource is more competitive. that able to optimize work. Researchers choose pelton
turbine as impulse and francis turbine as reaction.
TABLE I. ELECTIFICATION RATIO DEVELOPMENT
Turbine pelton is the type turbines who use reaction
Area 2009 2010 2011 2012 2013 2014 impulses from power hydrolysis. Technique convert
RE Sumatera 62,7 65,0 71,4 76,2 81,0 84,5
RE Jawa-Bali 67,6 70,5 73,6 78,2 83,2 87,0
potential energy water into mechanical energy on
RE Indonesia 50,6 52,6 59,0 64,6 70,5 73,9 wheels water turbine be conducted through impulses, so
Timur that turbine pelton also called the impulse turbine. The
RE Indonesia 63,5 66,2 70,5 75,3 80,4 84,0 principle impulses namely the rotor in an impulse
a.
RUPTL PLN 2015-2024 turbine rotating due to the collision of fluid pressurized

978-1-5090-1640-2/16/$31.00 ©2016 IEEE 185

directed by a nozzle to the rotor the, while the rotor where,
turbine reaction rotating a result of pressure fluid itself = major loss (m)
that out of the end of blades through a nozzle. With ℎ = minor loss (m)
increasing the speed a turbine with way to increase the Re = Reynolds number
number of a nozzle capable of increase the resulting
L = pipe length (m)
turbine. Other than turbine pelton having the same
namely fit on a head high, arrangement speed good and D = pipe diameter (m)
construction simple. K = coefficient of losses
V = fluid velocity (m/s)
Technique conversion of potential energy water into g = gravity (m/s²)
mechanical energy on wheels water turbine be
conducted through a reaction. So that turbine francis
also called the turbine reaction. Reaction processes that C. Power Calculations
is where turbine can produce torque by using pressure
or mass fluid .Pressure of a fluid turns on when passing Hydraulic power of water turbine,
the runner as in a picture 2.6 .In this type of turbine ℎ = . . . . (2.5)
required a kind of blade in casing to control a working where,
fluid and turbine it should be submerged fully on a = water density (998-1000 kg/m3)
working fluid .Flow on turbine francis is into, have = gravity (9,81 m/s2)
input axial in and discharge radial out. The main part of = flow rate (m3/s)
francis turbine are spiral case, guide vanes/blade
managing, the runner, water pipe services offered/the = total head, Hp+Hv+Hz (m)
draft tube. = turbine efficiency
B. Head loss Mechanical power of turbine,
Fluid flow through a pipe having obstacles of voltage = (2.6)
sliding viscosity in a fluid and occurring turbulent = . (2.7)
along the flow in a pipe, where dependent on =
. .
(2.8)
roughness (roughness) material pipe. These obstacles
called friction pipes and usually measured in a unit where,
head meters a fluid, where called also as loss head due = torque (Nm)
to friction in pipe. Major loss in laminar flow, = angular velocity (rad/s)
= (2.1)
= force (N)
= length of force (m)
Then for major loss in turbulent flow, = RPM
= (2.2) Electricity power of turbine,
= . (2.9)
Value of f is friction factor or Darcy’s friction factor where,
which are get from Moody Diagram.
= voltage (volt)
= current (ampere)

III. METHODOLOGY
A. System Design
First of all in this research is testing system design.
This system is collaborating from pelton and francis
turbine that have been built with system dimension. The
design was making with Computer Added Design
(CAD) Solid Works 2014x64 Edition SP01.

FIG 1. MOODY DIAGRAM

Minor losses can be calculated as,

= (2.3)

= (2.4)

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 fluid, nozzle, casing, reservoir and inverter.
Specification of components that used in this method is
shown in Table 2,

TABLE II. COMPONENTS SPECIFICATION

No Components Detail
Type: centrifugal Maximum head: 20
pump meters
Brand: Pedrollo Input power: 1300
Flow rate: 50-350 watts
1 Pump
lt/m Output power: 750
Installation: serial, watts
parallel Frequency: 50 Hz
Quantity: 2 pumps ID, OD: 1,5 inch
Material: OD: 1.9 inch (0.045
Polyvinyl meter)
Chloride (PVC) ID: 1.773 inch
Schedule: SDR (0.0468 meter)
2 Pipe 32.5 PVC pipe Thickness: 0.06 inch
Brand: Rucika, (0.0018 meter)
Maspion, Wavin Weight: 1.493
Size: 1.5 inch kg/meter
FIG 2. SYSTEM DESIGN OF HYDROPOWER TESTING SYSTEM
(0.0381 meter)
Knee/elbow: 18 Reducer: 5 pcs (1½
The fluid is patch on reservoir and then absorb by 3 Fitting
pcs dim to 1 dim), 1 pcs
pump to get head and debit. From pump the water flow T junction: 9 pcs (1 dim to ½ dim)
Ball valve: 5 pcs
into the turbine trough PVC pipe. In piping system will Fluid: air Density : 1000 kg/m3
be analyzed major and minor head loss. The angular Temperature: Viscosity : 8x10-3
velocity of pump is set by variable frequency drive in 4 Fluid 25°C Ns/m2
Type :inner flow -
range 30-50 Hz to condition the debit. Measuring turbulent
component in this system are rope brake torque, Material: Teflon - Length: 8,3cm - ulir
tachometer, pressure gauge, flow meter. To get lathe dalam
5 Nozzle
ID: 11mm, 12mm,
mechanical power are use rope brake torque to 13mm
calculate the load and proximity sensor which Material: acrylic Dimension:
6 Pelton Casing
integrated with pulse meter display to get the value of Thickness: 5mm 53,3x25x27 cm
Material: stainless Dimension: 45x2,5
angular velocity. Figure 2 show the diagram in testing 7 Sliding shaft
steel cm
system, Material: polymer Capacity: 240 liter
8 Reservoir Dimension: Discharge: valve ¼
60x85x50 m dim
Type: Variable Brand: Schneider
Frequency Drive Altivar
Pump control/
9 Power: 1,5 kW – ATV12HU15M2
inverter
2HP, Frequency:
50Hz
Type: Glass tube, Capacity: 25 m3/h
10 Flowmeter
polymer
Type: proximity Output: Pulse meter
Proximity
11 sensor 90mm, LRN5, Autonics
sensor
Autonics
Suction: -75cmHg Brand: WiKA
Pressure s/d 3kg/cm2
12
gauge Discharge: 0 s/d 3
bar

From the components above then it is assembly into

testing system. The objects are pelton and francis
FIG 3. BLOCK DIAGRAM OF TESTING SYSTEM turbine. In pelton turbine researcher varying four types,
there are nozzle distance to bucket, impulse velocity,
number of nozzles, nozzle’s angle of attack. In francis
B. Testing System turbine is varying flow rate using variable speed drive
In this testing system including supported that drive to motor of pumps. Table 3 shows steps,
component piping system which contain from pumps, scope and limitation of this research.
piping, fitting pelton turbine and francis turbine. The
system is in set and assembly in order to integrate as
figure 2. There are some supported components like
piping as flow line, fitting as flow control, water as

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 FIG 4. NOZZLE DISTANCE TO MECHANICAL POWER

TABLE III. STEP AND LIMITATION PROBLEMS

Variations Steps Problems Limitation
Pelton Turbine
1. Nozzle Varying nozzle distance Pelton turbine double bucket
distance to bucket by set the 16 pcs.
to position of sliding shaft. Using 1 nozzle with
bucket Distance variations: diameter 13mm.
50mm, 60mm, 70mm, Ball valve fully opened.
80mm. VFD setting in frequency
40-50 Hz.
2. Impulse Varying output area of Pelton turbine double bucket
velocity nozzle. 16 pcs.
Diameter variations: Using 1 nozzle (1st flow).
11mm, 12mm, 13mm Ball valve fully opened. FIG 5. IMPULS VELOCITY TO MECHANICAL POWER
Distance bucket to nozzle is
60mm.
VFD setting in frequency
40-50 Hz.
3. Number Varying number of Pelton turbine double bucket
of nozzle, 1 nozzle and 2 16 pcs.
nozzle nozzles. Diameter of nozzle is 13mm.
VFD setting in the same
flow rate in pump with 1
nozzle and 2 nozzles with
frequency range 40-47 Hz.
4. Nozzle’s Varying angle of attack Pelton turbine double bucket
angle of in nozzle (2nd flow). 16 pcs.
attack Angle variations: 0°, 5°, Only running using 1st pump
-5°. and 2nd pump is off.
Ball valve fully opened.
Distance bucket to nozzle is
FIG 6.NUMBER OF NOZZLE TO MECHANICAL POWER
60mm.
Using nozzle with diameter
13mm.
Francis Turbine
1. Debit Set the motor velocity Set flow rate in frequency
of pump using Variable 40-50 Hz.
Frequency Drive Ball valve and guide vanes
(VFD). fully opened.

IV. SYSTEM ANALYZE AND CONCLUSIONS

Researcher analyze three parts, there are testing
system of pelton turbine and francis turbine, head loss
in piping system and relation between head loss and
mechanical power of turbine.

A. Result of testing system FIG 7. NOZZLE’S ANGLE OF ATTACK TO MECHANICAL POWER

There are four variations in pelton turbine and one in
francis turbine. First variation is distance of nozzle to
bucket. Figure 4-7 show the impact of system
variations to mechanical power in pelton turbine, and
figure 8 shows the impact of flow rate variation that
affected to head and mechanical power.

FIG 8. HEAD TO MECHANICAL POWER

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 In figure 4, Mechanical power largest in flow rate B. Head loss
get at a distance as far as 6mm. Formerly at a distance The calculation on head loss in hydropower testing
of 5 cm tested mechanical power increased on the 6 cm system in scale of laboratory indicates that each testing
1.13-2.8 watts as much as. Next on testing distance 7 in the system of having losses. Losses that occur quite
cm long and 8 cm has experienced a fall in some of the low with loss total value head start from 1.275 meters
form. In general trendline obtained similar. Reduction to 5.3 meters.
in the value of mechanical power at a distance 7 and 8
mm can be caused because the that are too far apart TABLE IV. HEAD LOSS VALUE IN TESTING SYSTEM
from the center to sudu emissions of so as to cause the
Test of Pelton Turbine (Distance and Velocity of
speed the flow of reduced because of the influence of impulse)
the acceleration of gravity and time on the fundamental 1 Losses mayor 0,198 m
kinematics equation. Losses minor 1,077 m
In diameter a nozzle 13 millimeter than 11 mm Total losses 1,275 m
within head same the speed with which produced Test of Pelton Turbine (Nozzle Angle)
Losses mayor 0,219 m
higher on 11 mm. this seems in testing in the same 2
Losses minor 2,047 m
flow rate 0.0014167 m3/s diameter a nozzle 11 mm Total losses 2,266 m
indicating absolute speed of 14.9 m/s and diameter to Test of Pelton Turbine (Number of Nozzle)
12 mm indicating absolute speed of 12,53 m/s while Losses mayor 0,367 m
diameter 13 millimeter experienced decrease in 3
Losses minor 2,546 m
absolute velocity of be 10.68 m/s. As we know, pelton Total losses 2,91 m
turbine is kind of impulses turbine which use impulses Test of Francis Turbine (Flowrate)
or absolute speed, so mechanical power would be Losses mayor 0,32 m
4
higher when given more speed. Losses minor 4,98 m
Total losses 5,3 m
In minimum flow rate testing 0.001389 m3/s with
head 5.82 m using one a nozzle reached power 4.24
watts and 7.43 watts with two a nozzle. In highest The highest loss occurred in francis testing which
testing at flow rate 0.00172 m3/s with head 8.6 meters, reach 5.3 meters, it dominated by minor loss 4.98
a nozzle reached power 6.27 watts and when using two meters. The minor loss mostly causes by flow meter
a nozzle able to achieve power 11.5 watts. This which have minor loss coefficient 7. Francis turbine
indicates that by adding two nozzles are able to test occurred at high debit so that shows a high speed,
increase value of angular velocity and torque. Velocity the case is likely to have a larger head loss due to the
that produced by two sides nozzles capable to increase function of the quadratic speed.
the value of torque. From the testing and analysis of hydropower testing
At large same flow rate 0.00186 m/s at head 10.04 system in scale of laboratory researcher conclude that
meters the largest mechanical power produced at an in Pelton turbine the mechanical power that produces
angle 5ᴼ amounting to 15,34 watts. At an angle normal affected by variable system of them distance of bucket
and nozzle, speed the flow, the number of a nozzle and
in 0ᴼ produce power 13.7 watts. Value the power
angles attack of a nozzle. As for the influence of the
produced at an angle 0ᴼ are nearing power mechanical most significant is on variations in the quantity of a
at an angle -5ᴼ amounting to 13.64 watts. Increases at nozzle where power mechanical produced capable of
an angle -5ᴼ to 0ᴼ amounting to 1.07 times and an being improved to the average until 1.8 times, from
increase of 0ᴼ to 5ᴼ was amounting to 1.2 times. From 6.27 watts be 11.5 watts. Turbine francis performance
the testing a fourth of this capable of got that the power capable of maximum in discharge 0.0042 m3/s, in each
raised water turbine influenced long arms forces acting increase discharge 0.2 m3/h increased mechanical
on buckets. Although in variation 5ᴼ the power power 0.1 watts. Comparison of raised turbine pelton
produced capable of maximum, but a torrent of water and turbine francis having a diameter of same is
not all about buckets so many streams wasted and significant .Upon variations discharge same 0.00347
capable of destructive casing turbine pelton. m3/s pelton turbine excite resources to 5,5 watts and
Figure 8 indicates the influence of flow rate in water francis turbine is 1,3 watts. Significant differences
turbine influential comparable to mechanical power, attributed of head loss. In francis turbine total loss
the bigger flow rate then raised mechanical power. reach 5.3 meters and in pelton turbine only 2.9 meters.
Speed turn turbine francis tending to small ranged from Therefore, with the same condition of testing systems
62-91 speed turn to torque between 0.2 until 0.25 Nm. produced different power due to the influence of head
On function y (f(y) seemed that the power raised loss.
turbine francis tending to small.

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 [4]. B.R. Munson, D.F Young and T. H. Okiisshi,
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