SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT FINAL REPORT
Submitted To:
Mr. ANUP K.C.
Project Coordinator
July 2014
Authorization
We hereby declare that we are the sole author of the project.
We authorize the Kathmandu University to lend this report to other institutions or
individuals for the purpose of scholarly research. We further authorize the Kathmandu
University to reproduce the report by photocopying or by other means, in total or in
part, at the request of other institutions or individuals for the purpose of scholarly
research.
____________________________________________________________________
Nischal Pokharel, Pradeep Parajuli, Pratik Koirala, Rejit Dulal
July 2014
ii
CERTIFICATION OF APPROVAL
Study of Ultra Low Head Turbine for Nepal
By:
This is to certify that we have examined the above research project and have found
that it is complete and satisfactory in all respects, and that any and all revisions
required by the report examination committee have been made.
_________________________________________
Prof. Dr.-Ing. Ramesh Kumar Maskey
[Supervisor]
Department of Civil and Geomatics Engineering
_________________________________________
Dr. Hari Prasad Neopane
Associate Prof. & EnPe-MPPOES
[Co-supervisor]
Department of Mechanical Engineering
July 2014
iii
ACKNOWLEDGEMENT
We would like to thank our supervisor Dr. Ramesh Kumar Maskay for extending
our ideas and field of imagination and making us realize to approach a project in such
a way that it can be usable in any form or way. He has always been supportive and
provided us the idea of the models of the turbine and its beneficiaries.
We are grateful to our co-supervisor Dr.Hari Prasad Neopane during the whole
semester for sharing his great enthusiasm for all things innovative, scientific and
engineering of the fluid system through the turbine.
Mr. Anup K.C., our project co-ordinator is another person we would like to thank for
his suggestion, guidance and motivation in our works by giving weekly feedback of
our work. We are deeply indebted to his contributions in this project.
We thank Mechanical Workshop for helping us with the equipment and devices as
well as the tools required for model preparation of our project. Last but not the least,
we would like to thank our department for providing us this opportunity of doing the
project.
iv
Contents
Authorization .................................................................................................................. ii
CERTIFICATION OF APPROVAL .............................................................................iii
ACKNOWLEDGEMENT ............................................................................................. iv
LIST OF FIGURES ...................................................................................................... vii
ABSTRACT ................................................................................................................viii
LIST OF ABBREVIATIONS ....................................................................................... ix
LIST OF SYMBOLS ...................................................................................................... x
CHAPTER 1 INTRODUCTION AND BACKGROUND ........................................... 11
1.1 Introduction ......................................................................................................... 11
1.2 Background ......................................................................................................... 12
CHAPTER 2 OBJECTIVES ........................................................................................ 13
CHAPTER 3 SCOPE AND LIMITATION ................................................................. 14
CHAPTER 4 METHODOLOGY ................................................................................. 15
CHAPTER 5 LITERATURE REVIEW ....................................................................... 17
CHAPTER 6 SYSTEM OVERVIEW AND OPERATING PRINCIPLE ................... 19
6.1 System Overview: ............................................................................................... 19
6.2 Operational Principles: ....................................................................................... 19
6.2.1 Force due to Hydraulic Pressure Difference: ............................................... 21
6.2.2 Counter-acting Acceleration Force .............................................................. 21
6.2.3 Idealized Output Power ................................................................................ 22
6.2.4 Efficiency ..................................................................................................... 22
CHAPTER 7 WORKS ACCOMPLISHED ................................................................. 23
7.1 Discharge measurement in Roshi khola canal .................................................... 23
7.2 Development of the model design: ..................................................................... 23
7.2.1 First Model Preparation: .............................................................................. 24
7.2.2 Second Model Preparation: .......................................................................... 24
7.2.3 Third Model for testing and data analysis: ................................................... 25
CHAPTER 8 PROBLEMS FACED ............................................................................. 31
CHAPTER 9 GANTT CHART .................................................................................... 32
vi
LIST OF FIGURES
vii
ABSTRACT
This paper deals with new concept of exploitation of very low head hydropower sites,
where the fall height is less than 5 m. The ultra-low head (ULH) turbine is the subject
of this research, which is suitable for small heads, discharges with little variability,
easy to manufacture and with low costs associated.
The ULH turbine we aimed to study works on the principle of static pressure
difference. Two models were built for the study of operational principle. This was
followed by scale model testing, the results of which are used to estimate the
performance. The result of the testing was proved beneficial for making a simple
model of the turbine assembled in the test rig which was later on tested too and
analysis was made on the outcomes. We made a design of whole assembly in the solid
work. This design is mainly focused on the study rather than the production.
The main reason of the study was the ever increasing energy demand and the adequate
amount of water resources in our country that has not till been utilized in spite of the
high potentiality.
viii
LIST OF ABBREVIATIONS
cm
centimeter
L/s
meter
m/s
m3/s
MW
megawatt
Newton
Nm
Newton meter
rpm
second
ULH
ultra-low head
Watt
ix
LIST OF SYMBOLS
d1
[m]
d2
[m]
[m]
FA
[Newton, N]
FP
[Newton, N]
[m]
[m]
discharge
blade depth
[m/s2]
[m3/s]
[m]
upstream velocity
[m/s]
downstream velocity
[m/s]
[kg/m3]
density of water
theoretical efficiency
[-]
11
The concern now, is regarding the best use of low head and low discharge running water in the
rivers. Few research has been done so far in this. The turbine that can be fitted for this is ultra
low head (ULH) turbine over which we are focused.
In context of Nepal, mainly Pelton and Francis Turbine and few Kaplan turbine has been used in
the industrial hydroscale [4]. As we all know Nepal, which is the second richest country in water
sources has unlimited amount of small rivers and streams where the installation of ULH turbine
is possible.
It is the demand of time to install such a turbine in the country like Nepal to overcome and
mitigate the energy problem in different sites. The majority of very low head hydropower
installations can be done on natural or man-made rivers and canals with little or no water storage
capacity. Man-made sites include industrial sites such as water treatment plants, navigation and
irrigation canals in Terai. Thus, if we have such a huge potentiatity, then why cant we step up
for this?
1.2 Background
Till now, very much has been done in the field of the hydroelectricity for the production of the
electricity with high head, moderate and high discharge. For the developing country where the
hydro sources are limited or in considerable views, steps for the moderate or low production of
the electricity under 10 MW, very few initiatives could be witnessed.
Ultra-low head turbines are meant for this usage of producing hydroelectricity under the
condition of low head and low discharge [1]. The resulting amount of electricity may not be that
much significant but would be reliable for the developing nations for hydro aspects. It is because,
the use of the ultra-low head turbine would be beneficial for such nation where the sources of
water are small rivers, river basins and canals. And where the low head will be the case.
And for the various rivers and small streams and for even with low water storing capacity, ultralow head turbine is the most feasible one which could even serve our rural communities with
ever longing energy problems.
12
CHAPTER 2 OBJECTIVES
This project emphasizes on the following major goals which comprises of other goal line:
Study of the scope of the low head and low discharge turbines and conditions and
materials required for its usage, if feasible.
Work out with the prospects and design aspects of the low head turbine installations.
Findings regarding the aesthetics of the ultra-low head turbine, its reliability,
functionality and selection of sites and future proceedings on its design.
Issues regard of the work roots for low head turbine, implications, and efficiency.
Design and the installations arrangement of the ultra-low head turbine based on the static
pressure difference principle.
Design of the test rig for testing purpose thereby determining output power, efficiency
etc.
13
This project aims for studying the possibilities of using ultra-low head turbine in possible
site such as irrigation canal in Terai region, man-made sites including industrial sites such
as water treatment plants.
In this project we researches on simple applicable design of ultra-low head turbine and
canal requirements for that designed turbine. Detailed design on the consideration of
velocity triangle has not been done.
The project aims to fabricate small turbine and make a test rig for testing purpose using
sufficient discharge.
14
CHAPTER 4 METHODOLOGY
The flow chart of the methodology applied is as follows:
Literature review
Model Preparation
Second Model
Failed, so
Failed, so
Third Model
If succeeded
If succeeded
Design Modification
Working with the relevant information and the time factors, our project dynamics had several
efforts to concrete the knowledge about the hydro based project work. Initiatives taken by us
with the expert guidance resulted some fairsome tale of knowledge in hydro technology whereas
the longevity of the research works in this area was the goal of our project methods.
Literature Review: The initial basic of the methodology was the prime effort to study
the literature of the hydro power and its status here over. After the periods of the study
and overlook in the areas regard to ultra-low head turbine, we draw to a conclusion that
the ultra-low head turbine would be answer to small scale hydropower in the areas with
low river discharge, small canals, small water reservoirs, low head sites and alike. The
study of the ultra-low head turbine in time was accomplished to conclude that no hydro
power in nation is using this system to generate electricity significantly then.
Site visit: Initially, though we were focused in doing research in Terai belts, later on
through the literature review and expert guidance, we limited our project in Kathmandu
15
University premises as lot can be done for ULH turbine here over too. Our practical
approach begin with the preparation of a turbine model to test it in nearby Roshi khola
canal. The various parameters for the design were taken into account. The flow of water,
discharge rate, cross sections, velocities of flow, head were the prime parameters into
consideration.
Model Preparation: We step forward for the ideas of this prototype design. The
preliminaries required for the prototype making was gathered to set a small model of the
ultra-low head turbine in the workshop. Consecutively three models of the turbine were
made after the first one had failed with the principle of the static pressure difference and
second one created difficulty of assembly in the canal. The initial model was tested in a
local Roshi khola canal to observe its working principle and functionality. The design of
the prototype was in part with our ambition of the project to date. The exemplary second
model of the ultra-low head turbine was made in the workshop using the sheet metal and
plywood with nuts and rivets. Sheet metal was used for the making of the blades of
turbine and the pressure hub in the turbine. The lateral ways to impart the finish and close
the gap was made using the plywood in the both rounded ends. Unfortunately we were
unable to test this model due to the difficulty created in its assembly in canal due to use
of metal sheet. The final model having the hub and blades of the polyvinyl pipe that was
designed considering the designed criteria, was fabricated in our workshop which was
tested in the canal present nearby Roshi khola canal.
Design for the assembly of the turbine in the canal: Although the design of canal
assembly for the purpose of testing of second model was done in AutoCAD, we did not
test it, rather redesign was done for the testing of third model. Initially the design was
done in order to test it in a canal to be made nearby Fluid Mechanics laboratory with the
closed water system having the discharge of 18 L/s. But the test set up was made for the
testing in Panauti site due to insufficient head provided by the discharge of pump because
of the greater initial velocity.
16
Central hub: This is a horizontal cylinder which spans the width of the machine, and hub
diameter equal to the head of the site (H) upto 1.25 H [5]. The top of the hub is level with
or just above the upstream water surface and the bottom of the hub is level with the
downstream water surface.
Blades: The blades are the surface on which the waters energy is extracted. In the ULH,
they have almost same length as the diameter of the hub or head of the site [5]. They
extend radially from the hub, whilst twisting as they progress across the width of the
wheel. The blade can also be made airfoil in order to increase lift in the turbine that
increases the speed of the turbine.
Also depicted in figure are the main components of the wheel support structure, including:
Shroud: This curved section of river bed ensures that at least one entire blade is enclosed
within a close fitting channel. This prevents any leakage flow of water between and along
the diagonally mounted blades, entering from beneath the wheel.
from
the
sides
of
the
wheel.
J. & Co.]
well as the front. They also allow air to ventilate the compartments from the side of the
wheel [6]. This process allows the water to drain from the compartments with ease once
they have reached the downstream.
17
It requires inflow from side and back, therefore a gap of width G between canal wall and
turbine should be provided.
The turbine should have 8-12 blades with a preferred angle of 20 degrees.
The blade depth T should be 0.7 to 1.0 times the hub diameter D, T = 0.7 to 1.0 D.
The downstream water depth d2 should be ideally equal to the blade depth T, but not less
than 0.7 T otherwise efficiency drops significantly.
The width W should not exceed two times the hub diameter, W< 2D.
The ratio of the turbine width and canal width should be less than 0.7 to allow the flow of
water from side as well [5].
18
19
These two forces are assessed below using the following idealized model which illustrates the
working principle namely Static Pressure Difference principle [1].
Starting from first principles, the Pressure, P at a depth of water, h with density, of water,
under the influence of gravity, g is:
(1)
Fig. 3. Showing pressure acting on a simple vertical plate [Senior, J. & Co.]
Referring to the Fig. 3 above, consider a simple vertical plate which separates two dissimilar
depths of water, d1 and d2. The triangles represent the hydrostatic pressure. The forces on either
side of this plate of width, W, are F1 and F2:
(2)
(3)
It can be seen that the force on the plate acting from the deeper water, F1, is greater than that
acting from the shallower water, F2, and the total force acting on the plate, F, is:
(4)
If it is now imagined that the plate moves laterally with velocity, v, the power at the plate, P, is:
(
(5)
The above example illustrates the most important principle behind the ULH operation: that two
dissimilar depths of water acting across a vertical plate result in a force from which power can be
extracted. In reality, it is not practical to have a vertical plate which moves laterally and
indefinitely. Instead it is proposed that the plates, or blades, are mounted about an axle. This
20
configuration adds additional complexity to the analysis as the water must flow from the deeper
side of the turbine to the shallower side.
Fig. 4. Static Pressure difference in ultra low head turbine [Senior, J. & Co.]
and
becomes greater
is achieved beneath the hub, this acceleration of the water leads to a drop in
water level by
d
(7)
The force on the blades due to the hydraulic pressure FP acting on the blade therefore drops
(FP= Pressure Area of blade, A):
d
(8)
21
(10)
6.2.4 Efficiency
The idealized efficiency of the turbine is the ratio of ideal output power to input power, as given
below:
(11)
22
) for the turbine. Considering the head and discharge of the water in the canal to be
the determining parameters for the turbine installation, we concluded that Roshi khola canal is
suitable location for it.
23
) as per
our concept but not according to our operating principle. This deviation was mainly due to lack
of the hub in it. Hub acts as a blockage for the water discharge, thereby creating single passage
for the water flow which is beneath the turbine. Thus, ULH turbine is just like middle-shot
wheel, in which water enters the turbine as almost same height or more as that of the axis.
7.2.2 Second Model Preparation:
After the testing of the first model, we were aware that the failure of the principle was mainly
due to enough volumetric loss from the turbine. Unlike the first model, this model consists of
hub within it in order to remedy the problems faced of deviating from operating principle.
Considering the depth and width of the canal nearby Fluid Mechanics Lab in Kathmandu
University as primary parameter, we made another model using same materials as in first one.
This model was mainly based on the ratio of length (l) of the turbine and diameter (d) of the
hub such that l does not exceeds twice of d. Due to large leakage possibility from the
turbine, we were not able to test it as per our desire. Initially, we expected to prevent the leakage
using labyrinth and made arrangements for its testing as shown in AutoCAD drawing below. But
later on, we found the turbine needs certain design modification. As per our literature analysis
and supervisors suggestion, a final model is prepared in recent days. We are expected to test this
model and cast it, if it gives enough efficiency.
24
Fig. 8. Design of the turbine and its assembly for testing
The blade depth, T is 10.6 cm and the hub diameter, D is 15.24 cm to maintain their ratio
0.70.
The projected blade length (L) parallel to the axis of hub is 23 cm in order to maintain
the relation (L<2D).
Also, we are assumed to make following considerations while testing it.
The hub diameter D is to be maintained 1.2 to 1.25 times the head difference H in order
to reduce the turbulence losses during blade entry upstream.
The downstream water depth d2 is to be maintained equal to the blade depth T but not
less than 0.7 T in order to make efficiency significant.
The projected blade length is to be maintained less than 0.7 times the canal width.
The Fig. 9 shows the design of the turbine with shaft of 2.4 cm diameter attached to it with
centering.
25
Fig. 9. Turbine design with shaft fitted in it
26
Canal
Fig. 12. Site with closed loop water system for turbine testing
27
Experimental Procedure:
Fig. 13. Test set up of turbine assembly over the canal
First the test rig was made in the workshop. It was then taken to a canal nearby Roshi khola canal
and fitted in it as shown in figure below. Firstly, the speed of the turbine was recorded. The
obtained speed was 12 rpm.
After that, different discharges were sent to the test rig that varies the working head and
corresponding output power and effiency were calculated.
28
Data analysis:
Thus observed discharge, head and upstream velocity changes are used to find the output power
and efficiency as follows:
Table 1. Calculation of the theoretical out power and efficiency by varying the discharge
v2 (m/s) d1 (m)
H (m)
Q (m3/s) FP (N)
FA (N)
POUT (W) PIN (W)
efficiency
0.65
0.14
0.07
0.016
12.8
5.2
5.0
11.00
45.14
0.70
0.15
0.08
0.017
14.4
6.4
5.6
13.47
41.81
0.75
0.16
0.09
0.018
16.0
7.7
6.2
16.15
38.48
0.79
0.17
0.10
0.019
17.5
9.1
6.7
19.07
35.15
0.84
0.18
0.11
0.021
19.0
10.6
7.1
22.20
31.82
0.89
0.19
0.12
0.022
20.4
12.2
7.3
25.56
28.49
0.93
0.2
0.13
0.023
21.7
13.9
7.3
29.15
25.16
0.98
0.21
0.14
0.024
23.0
15.7
7.2
32.96
21.83
29
1.03
0.22
0.15
0.025
24.3
17.6
6.8
36.99
18.50
8.000
6.000
4.000
2.000
0.000
5.0
5.6
6.2
6.7
7.1
7.3
7.3
7.2
6.8
30
31
Activity
1.
Concept
development
Literature review
2.
3.
4.
5.
6.
7.
8.
March
April
May
Model
preparation
for
testing
Site Selection for
testing
Progress
report
and
midterm
presentation
Material
collection and test
rig preparation
Testing of the
model and data
analysis
Final
Presentation
32
June
July
33
References
[1] Senior, J., Wiemann, P., & Muller, G. (n.d.). THE ROTARY HYDRAULIC PRESSURE
electric
power
plants.
(cited
on
2014
June
25).
Retrieved
from
http://www.hydropowerstation.com/
[4] Pandey, B. (cited on 2014 June 28) . Status of Hydroelectricity in Nepal: Potential and
Challenges. Retrieved from http://www.binodpandey.wordpress.com/
[5] Harvey, A, & Brown, A (1992). Micro-Hydro Design Manual.Stockholm: ITDG Publishing.
[6] WIEMANN, P. (2006) Neue wirtschaftliche und technische Mglichkeiten der
Stromerzeugung durch innovative Kleinwasserkraftwerke (New economic and technical
possibilities for energy generation with innovative small hydropower converters, in
German), Diplomarbeit, Universitt Kalsruhe/ University of Southampton.
[7] Marjang, N. and Merkley, G. 2009. Surface Velocity Coefficients for Application of the
Float Method in Rectangular and Compound Open Channels. Irrigation Science 27:457-470.
34
Appendix
35
36
d
d
0.035 m
= 7.3 W
37