Tokyo Electric Power Micro Hydro

Module 4.
3 Micro-Hydro Micro-
4.3.1 Designing
Tokyo Electric Power Co. (TEPCO)
Workshop on Renewable Energies March 17, 2005 Majuro, Republic of the Marshall Islands
Contents
Design for Civil Work Calculation of Head Loss Design of Electrical and Mechanical Equipment
e7 / PPA Workshop on Renewable Energies
Design for Civil Work

1.
(a) (b) (c) (d) (e) (f) (g) (h) (i) (j)
Selecting a Type of Intake Weir or Dam

Concrete gravity dam Floating concrete dam Earth dam Rockfill dam Wet masonry dam Gabion dam Concrete reinforced gabion dam Brushwood dam Wooden dam Wooden-frame dam with gravel

1-1.Concrete gravity dam
Concrete is used for the construction of the entire body. Foundation : Bedrock River conditions : Not governed by gradient, discharge or level of sediment load Intake conditions: Good interception performance and intake efficiency

1-2. Floating concrete dam
Lengthened infiltration path of the foundations by means of cut-off, etc. to improve the interception performance Foundations : In principle, gravel River conditions : Not affected by the gradient, discharge or level of sediment load Intake conditions: Good interception performance and intake efficiency
Cut-off Longer
5

1-3. Earth dam
Earth is used as the main material for the body. The introduction of a riprap and core wall may be necessary depending on the situation. Foundations : Variable from earth to bedrock River conditions : Gentle flow and easy to deal with flooding Intake conditions: High interception performance and good intake efficiency

1-4. Rockfill dam
Gravel is used as the main material for the body. The introduction of a core wall may be necessary depending on the situation. Foundations : Various, from earth to bedrock River Conditions : River where an earth dam could be washed away by normal discharge Intake conditions: Limited to the partial use of river water due to the low intake efficiency

1-5. Wet Masonry Dam
Filling of the spaces between gravel with mortar, etc. Foundations : Various, from earth to bedrock River conditions : Not affected by the gradient, discharge or level of sediment load Intake conditions: Good interception performance and intake efficiency

1-6. Gabion Dam
Gravel is wrapped in metal net to improve integrity. Foundations : Various, from earth to bedrock River conditions : River where a rock-fill dam could be washed away by normal discharge Intake conditions: Limited to partial use of river water due to the low intake efficiency

1-7. Concrete Reinforced Gabion Dam
Reinforcement of the gabion surface with concrete Foundations : Various, from earth to bedrock River conditions : River where the metal net could be damaged due to strong flow Intake conditions: Applicable when high intake efficiency is required
10

1-8. Brushwood Dam
Simple weir using locally produced tree branches, etc. Foundations : Various, from earth to gravel layer River conditions : Loss due to flooding is assumed Intake conditions: At a site with a low intake volume or intake from a stream to supplement the droughty water
11

1-9. Wooden Dam
Weir using locally produced wood Foundations : Various, from earth to bedrock River conditions : Relatively gentle flow with a low level of sediment transport Intake conditions: A certain level of intake efficiency is ensured with a surface coating, etc.
12

1-10. Wooden-Frame Dam with Gravel
The inside of the wooden frame is filled with gravel to increase stability. Foundations : Various, from earth to bedrock River conditions : River at which a rock-fill dam could be washed away by normal discharge Intake conditions: Limited to the partial use of river water due to the low intake efficiency
13

Decision of weir height
(1). Elevation of waterway considering: - Geology, topography, existing structures, etc. (2). Riverbed rise downstream - Possibility of change of riverbed elevation
(3). Easy flushing sedimentation materials in front of intake (4). Head acquisition and construction cost (5). Backwater effect
14

2. Intake
Side intake - Typical intake - At right angles to the river Tyrolean intake
- Along the weir - Simple structure - Affected by sedimentation during flooding - More maintenance required
Side Intake
Tyrolean Intake
15

3. Settling Basin
Function: Settles and removes suspended materials of all sizes that could adversely affect the turbine. Spills out excess water from spillway
10 15
D am Intake Stoplog Spillway Flushing gate
Headrace
1.0
Conduit section
2.0
hsp+15cm
Widening section Intake
Settling section Bsp
Stoplog
hi
hs
h0
ic=1/201/30
Sediment Pit
bi
Flushing gate
16

4. Headrace
Function: Conveys water from the intake to the forebay Spillways provided along the headrace for excess water Flow Capacity Qd = [ A R 2/3SL 1/2 ] n
where, A: Cross-sectional area R: R = A/P P: Length of wet sides SL: Longitudinal slope of headrace n: Coefficient of roughness
17
n = 0.025 n = 0.030
Simple earth channel
Lined channel (Rock and stone)
n = 0.020
n = 0.015
Wet masonry channel
Concrete channel
18

n = 0.015 n = 0.015
Wooded-fenced channel
n = 0.015, 0.012
Box culvert channel
Closed pipe (Hume pipe, steel pipe)

19

5. Forebay Function:
Regulates fluctuating discharge in the penstock and the headrace caused by load fluctuation. Has final function to remove materials (silt, sand), debris (leaves, trash, driftwood, etc.) in the water
Attached Structure:
Spillway Screen (Regulating gate)
20

6. Penstock
Conveys water under pressure from the forebay to the turbine Materials: Steel, resin (Hard vinyl chloride, Howell, Fibre Reinforced Plastics) Diameter of pipe d = C (QdVopt)0.5
where,
e7 / PPA Workshop on Renewable Energies SI unit d C Qd Vopt Diameter Coefficient Designed discharge Optimum velocity -m 1.273 m3/s 1.0 to 2.8 m/s Imperial unit - ft 2.306 ft3/s 3.38 to 9.2 ft3/s
21

Diameter of penstock affects output of a power plant. Increase of Diameter- Increase of Output - Increase of Cost Optimum Diameter to be determined
Output Limitation by Diameter of Penstock
100.0 90.0 80.0 70.0 60.0 50.0 40.0 30.0 20.0 10.0 0.0
Length of Penstock = 300ft, Coefficiency of Roughness = 0.013
D=10in D=12in D=14in D=16in D=18in
Output (kW )
0. 10 0. 15 0. 20 0. 25 0. 30 0. 35 0. 40 0. 45 0. 50 0. 55 0. 60 0. 65 0. 70 0. 75 0. 80
Discharge (ft3/ s)
22

7. Powerhouse Function:
Provides shelter for the electro-mechanical equipment (turbine, generator, control panels, etc.)
The size of the powerhouse and the layout:

Determined taking into account convenience during installation, operation and maintenance.
Foundation:
Classified into two: For Impulse turbine -Pelton turbine, Turgo turbine or cross-flow turbine, etc. For Reaction turbine -Francis turbine or propeller turbine, etc.
23

a. Foundation for Impulse Turbine
The figures shows the foundation for the cross flow turbine. There is a space between the turbine and the surface of discharged water.
A hc ={
1 .1 Q d 2 9 .8
1/ 3
30 50cm
F lo o d W a ter L e vel(M a xim um )
H L3 (see R e f.5 -3 ) 30 50cm
A fterb a y
T ailrac e c anne l
O utle t
S ection A -A
bo b o : d ep end s o n Q d and H e
20cm b
2 0 cm
24

b. Foundation for Reaction Turbine
The below figures show the foundation for the Francis turbine. The outlet of the turbine is installed under the level of discharged water.
A
d3 Hs depens on characteristic of turbine
hc={ Hs
30 50cm 20cm
1.1Qd 9.8
1/ 3
Flood Water Level(Maximum)
1.15 d3 2 3 1.5d3 H L3 (see Ref.53)
Pum p
FloodW L (M um ater evel axm )
A Section A-A
G ate H3 L
1.5d3
25
Calculation of Head Loss

Head losses are indicated by the following figures at hydropower systems. HL1 can be calculated easily as the differential water level between the intake to the forebay tank. Similarly HL3 can be calculated as the differential level between the center of the turbine to the tailrace.
Intake Settling Basin Headrace HL1 Forebay Penstock HL2 H Hg
Powerhouse
He
HL3
He = Hg (HL1 + HL2 + HL3) where, He: Effective head Hg: Gross head HL1: Loss from intake to forebay HL2: Loss at penstock HL3: Installation head and loss at tailrace
Tailrace
26
Calculation of Head Loss

The head loss at the penstock (HL2) can be calculated by the following equations. HL2 = hf + he + hv + ho where,
hf: Frictional loss at penstock he: Inlet loss hv: Valve loss ho: Other losses (Bend losses, loss on changes in crosssectional area and others)
27
<Reference > Head Loss at Penstock

(1) Frictional Loss hf = f (Lp/Dp ) Vp2/2g where, hf: Frictional loss at penstock (ft) f: Coefficient on the diameter of penstock pipe (Dp) f = 185 n2/Dp1/3 Lp: Length of penstock (ft) Vp: Velocity at penstock (ft/s) Vp = Q/Ap g: Acceleration due to gravitation (32.14 ft/s2) Dp: Diameter of penstock pipe (ft) n: Coefficient of roughness (steel pipe: n = 0.012, plastic pipe: n = 0.011) Q: Design discharge (ft3/s) Ap: Cross sectional area of penstock pipe (ft2) Ap = 3.14 Dp24.0
28

(2) Inlet Loss he = fe Vp2/2g he: Inlet loss (ft) fe: Coefficient on the form at inlet. Usually fe = 0.5 in micro-hydro scheme hv = fv Vp2 /2g hv: Valve loss (ft) fv: Coefficient of the type of valve fv = 0.1 ( butterfly valve)
where,
(3) Valve Loss

where,
(4) Others Bend loss and loss on changes in cross-sectional area are considered other losses. However these losses can be neglected in micro-hydro schemes. Usually, people planning micro-hydro schemes must take account of following margin for other losses. ho = 5 to 10% (hf + he +hv)
29

In SI Unit (1) Frictional loss Frictional loss (hf) is the biggest of the losses at penstock. hf = f (Lp/Dp ) Vp2/2g where,
hf: Frictional loss at penstock (m) f : Coefficient on the diameter of penstock pipe (Dp). f = 124.5n2/Dp1/3 Lp: Length of penstock (m) Vp: Velocity at penstock (m/s) Vp = Q/Ap g: Acceleration due to gravity (9.8m/sec2) Dp: Diameter of penstock pipe (m) n : Coefficient of roughness (steel pipe: n = 0.012, plastic pipe: n = 0.011) Q: Design discharge (m3/s) Ap: Cross sectional area of penstock pipe (m2) Ap = 3.14Dp2/4.0
30

(2) Inlet Loss he = fe Vp2/2g he: Inlet loss (m) fe: Coefficient on the form at the inlet Usually fe = 0.5 in micro-hydro schemes. hv = fv Vp2 /2g hv: Valve loss (m) fv: Coefficient on the type of valve, fv = 0.1 (butterfly valve)
where,
(3) Valve Loss

where,
(4) Others Bend loss and loss due to changes in cross-sectional area are considered other losses. However, these losses can be neglected in micro-hydro schemes. Usually, the person planning the micro-hydro scheme must take account of following margins as other losses. ho = 5 to 10% (hf + he +hv)
31
Design of E/M Equipment

Equipment and Functions
1. Inlet valve: Controls the supply of water from the penstock to the turbine. 2. Water turbine: Converts the water energy into rotating power. 3. Turbine governor: Controls the speed and output of the turbine 4. Power transmission facility: Transmits the rotation power of the turbine to the generator. 5. Generator: Generates the electricity from the turbine or its transmitter. 6. Control panels: Controls and protects the above facilities for safe operation. 7. Switchgear (with transformer): Controls the electric power and increases the voltage of transmission lines, if required
Note: Items 3, 6 & 7 above may sometimes be combined in one panel.
32

1. Inlet Valve
33
Design for E/M Equipment

2. Water Turbine Types:
Impulse turbines: Rotates the runner by the impulse of water jets by converting the pressure head into the velocity head through nozzles. Reaction turbines: Rotates the runner by the pressure head.
Type
Head High Medium Crossflow Turgo Fransis Pump-as-Turbine Low Crossflow Propeller Kaplan Pelton Turgo
Impulse Reaction
34

Selection of turbine type
(3,280)
i.e.: H = 25m, Q = 0.45m3/s 3 Cross Flow

(82ft)
(15.88ft /s)
1000
(m, ft)
or Horizontal Francis
Horizontal Pelton
Effective Head 100
(328)
Vertical Francis
(32.8)
10
Cross Flow Horizontal Francis Horizontal Propeller
(3.28)
1 0.01 (0.3529)
0.1 (3.529)
1 10 (35.29) (352.9) 3 3 W ater Discharge (m /s, ft /s)
100 (3,529)
35
Design of E/M Equipment Cross-Flow Turbine
36
Design of E/M Equipment Cross-Flow Turbine
Speed Governor
Water
Cross-Flow W/T Cross-
Guide Vane
37
Design of E/M Equipment Francis Turbine
38
Design of E/M Equipment Francis Turbine
39
Design of E/M Equipment Tubular Turbine
40
Design of E/M Equipment Tubular Turbine Timing Belt

Generator Draft Tube
Guide Vane Propeller Runner (Wicket Gate)
41
Design of E/M Equipment Pelton Turbine
42
Design of E/M Equipment Pelton Turbine
43
Design of E/M Equipment Reverse Pump Turbine (Pump as Turbine)
44
Design of E/M Equipment Pico Hydro
45

3. Generator
Synchronous: Independent exciter rotor, applicable for both isolated and existing power networks Asynchronous (induction): No exciter rotor is usually applicable in networks with other power sources. In isolated or independent networks, it must be connected to capacitors to generate electricity.
Generator output:
Pg (kVA) = (0.0847 x H x Q x )/pf Pg (kVA) = (9.8 x H x Q x )/pf (in SI unit)
Where Pg: output (kVA) H: Net head (ft, m) Q: Rated discharge (ft3/s, m3/s) : Combined efficiency of turbine, transmitter & generator (%) pf: Power factor ( %). The value is based on the type of load in the system.
46

3. Generator
Speed and Number of Generator Poles - The rated rotational speed is specified according to the frequency (50 or 60 Hz) of the power network and the number of poles by the following formula: For synchronous generators: P (nos.) = 120 x f/N0 N0 (rpm) = 120 x f/P where, P : Number of poles f : Frequency (HZ) N0 : Rated rotation speed rpm) For induction generators: N (rpm) = (1-S) x N0 where, N : Actual speed of induction generator (rpm) S : Slip (normally S= -0.02) N0 : Rated rotation speed rpm)
47

4. Power Transmission Facility (Speed Increaser)
To match the speed of the turbine and generator. Gearbox type: The turbine shaft and generator shaft are coupled with helical gears with parallel shafts in one box with anti-friction bearings according to the speed ratio between the turbine and generator. The life is long but the cost is relatively high. (Efficiency: 95 97% subject to the type) Belt type: The turbine shaft and generator shaft are coupled with pulleys or flywheels and belts according to the speed ratio between the turbine and generator. The cost is relatively low but the life is short. (Efficiency: 95 98% subject to the type of belt) In the case of a micro hydro-power plant, a V-belt or flat belt type coupling is usually adopted to save the cost because the gear-type transmitter is very expensive.
48

5. Control Facility of Turbine and Generator
5.1 Speed Governor: The speed governor is adopted to keep the turbine speed constant because the speed fluctuates if there are changes in the load, water head or flow. (1) Mechanical type: Controls the water discharge constantly with the automatic operation of the guide vane(s) according to load. There are two types: Pressure-oil type Motor type Ancillary Equipment: Guide vane servomotor, pressure pump and tank, sump tank, piping or guide vane operated by electric motor
49

(2) Dummy load type: To balance both the actual load and dummy load using a thyristor i.e. to keep the total of both the actual and dummy load constant for the same generator output and speed. The load is controlled by an electronic load controller (ELC). The capacity of the dummy load is calculated as follows:
Pd (kW) = Pg (kVA) x pf (decimal) x SF where,

Pd: Pg: pf: SF: Capacity of dummy load (Unity load: kW) Rated output of generator (KVA) Rated power factor of generator Safety factor according to cooling method (1.2 1.4 times generator output in kW) to avoid over-heating the heater
50

5.2 Generator Exciter
In the case of a synchronous generator, an exciter is necessary for supplying field current to the generator and keeping the output voltage constant if the load fluctuates. Brush type: Direct thyristor excitation method. DC current for the field coil is supplied through a slip ring from a thyristor with an excitation transformer. (Low initial cost but high maintenance cost) Brushless type: The basic circuit consists of an AC exciter directly coupled to the main generator, a rotary rectifier and a separately provided automatic voltage regulator with a thyristor (AVR). (High initial cost but low maintenance cost)
51

5.2 Generator Exciter
Wiring diagram of exciter with brush
Wiring diagram of brushless exciter

PT
PT
CT Ex. Tr
AVR
Pulse Generator
(Speed Detector)
CT Ex. Tr
AVR
Pulse Generator
(Speed Detector)
Rotating section
Slip ring
DC100V G AC Ex
52

5.3 Single Line Diagram
The typical single diagram for a 380/220V distribution line
Magnet Contactor
NFB
Fuse
A x3 V Turbine
Hz
x3 Lamp Indicator x3
To Cust mer
G
Transmitter if required
ELC
Generator
(with Hz Relay)
Dummy Load
53

6.Control, Instrumentation and Plant Protection
6.1 Control Methods: Supervisory control method is classified into continuous supervisory, remote continuous control and occasional control. The operational control method is classified into manual control, single-person control and fully automatic control. The output control method is classified into output by single governor for independent network and water level control, discharge control and program control for parallel operation with another power source.
54

6.2 Instrumentation Pressure gauge for penstock Voltmeter with change-over switch for output voltage Voltmeter with change-over switch for output of dummy load (ballast) Ammeter with change-over switch for ampere of generator output Frequency meter for rotational speed of generator Hour meter for operating time KWH (kW hour) meter and KVH (Kvar hour) meter, which is recommended to check and summarize total energy produced by the power plant
55

6.3 Protection of Plant and 380/220V Distribution Line
Considering the same reason for cost saving in instrumentation, the following minimal protection is required for micro-hydro power plants in rural electrification. 1. Over-speed of turbine and generator (detected by frequency) 2. Under-voltage 3. Over-voltage 4. Over-current by NFB (No Fuse Breaker) or MCCB (Molded Case Circuit Breaker) for low-tension circuits. When items 1, 2 and 3 are detected by an ELC (with screw adjustment), the magnet contactor (MC) is activated and trips the main circuit of the generator.
56

Tokyo Electric Power Micro Hydro

Diunggah oleh

Informasi Dokumen

Deskripsi Asli:

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Tokyo Electric Power Micro Hydro

Diunggah oleh

Hak Cipta:

Format Tersedia

Module 4.

Design for Civil Work

Selecting a Type of Intake Weir or Dam

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

Design for Civil Work

Design for Civil Work

D am Intake Stoplog Spillway Flushing gate

Widening section Intake

Settling section Bsp

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Simple earth channel

Lined channel (Rock and stone)

Wet masonry channel

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Box culvert channel

Closed pipe (Hume pipe, steel pipe)

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

Design for Civil Work

Design for Civil Work

D=10in D=12in D=14in D=16in D=18in

Design for Civil Work

The size of the powerhouse and the layout:

Design for Civil Work

e7 / PPA Workshop on Renewable Energies

F lo o d W a ter L e vel(M a xim um )

H L3 (see R e f.5 -3 ) 30 50cm

Design for Civil Work

Flood Water Level(Maximum)

e7 / PPA Workshop on Renewable Energies

1.15 d3 2 3 1.5d3 H L3 (see Ref.53)

FloodW L (M um ater evel axm )

Calculation of Head Loss

e7 / PPA Workshop on Renewable Energies

Calculation of Head Loss

<Reference > Head Loss at Penstock

e7 / PPA Workshop on Renewable Energies

<Reference > Head Loss at Penstock

(3) Valve Loss

<Reference > Head Loss at Penstock