KATHMANDU UNIVERSITY

SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

A Proposal on Performance Testing of Micro Hydro & Laboratory Setup as the Fourth Year Undergraduate Project Works

Supervisor: Mr. Biraj Singh Thapa

Submitted by: Abinash Baral (41053) Rojan K. Katuwal (41089)

28 December 2011

ABSTRACT
This is the proposal submitted to Department of Mechanical Engineering in the project entitled Performance Testing of Micro Hydro & Laboratory Setup. The primary target of our project is to setup a laboratory for the testing of micro-hydro cross-flow turbines. The initial phase will include the dismantling of the previous test rig placed at pico-hydro turbine testing laboratory at Kathmandu University (KU) and re-installing it at the newly built turbine testing laboratory at KU. After, initial performance tests the latter stages will include modifications and improvements in the test rigs for other micro-hydro turbine testing. This project intends to study testing procedures adopted elsewhere and every possibility of implementation. The success of our project might ease and establish certain procedures of turbine testing, further relieving the pressure on micro hydro-power developers. Our aim is to study and test micro-hydro turbines and prepare hill charts of the turbine with a proper laboratory setup.

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TABLE OF CONTENTS

Abstract Chapter 1: Introduction 1.1 Rationale 1.2 Objectives Chapter 2: Literature Review Chapter 3: Methodology Chapter 4: Discussion 4.1 Laboratory test Chapter 5: Gantt Chart Chapter 6: Conclusion References

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CHAPTER 1

INTRODUCTION
1.1 Rationale
The easy availability as well as the abundance of falling water sources is the main inspiration for the project. Besides the environment friendly nature of micro-hydro powers, easy production is equally relevant in economy stripped country like ours. If simple procedures of turbine testing are used then optimization of the turbines will be easier. This is a good possibility of its wide acceptance among people that may even lead to establishments of micro-hydro systems at different parts of the country electrifying the rural and semi-urban communities.

1.2 Objectives
The main objectives of our project include: i. ii. iii. To test the efficiency of the 15 KW cross-flow turbine currently installed in the rig. To prepare hill chart of the same. To further test other micro-hydro turbines and prepare their hill charts.

The secondary objectives of our project include: i. ii. iii. To study other testing laboratory setup. To apply testing procedure considering availability and accuracy. To test micro-hydro turbines.

CHAPTER 2

LITERATURE REVIEW
Micro hydro is hydro power with electrical output of five to 20 kilowatts. Hydro power systems of this size benefit in terms of cost and simplicity from different approaches in the design, planning and installation than those which are applied to larger hydro power. Recent innovations in micro hydro technology have made it an economic source of power even in some of the worlds poorest and most inaccessible places. It is also a versatile power source. AC electricity can be produced enabling standard electrical appliances to be used and the electricity can be distributed to a whole village. Common examples of devices which can be powered by microhydro are light bulbs, radios, televisions, refrigerators and food processors. The purpose of a hydraulic turbine is to transform the water potential and kinetic energy to mechanical rotational energy. Various types of turbines exist to cope with different levels of head and flow. The two broad categories are: y Impulse turbines notably the Pelton, Turgo or the Banki-Michell (cross-flow) - in which water impinges or enters the runner, which is designed to change the waters direction and thereby extract the momentum from it with scarce change of pressure energy. y Reaction turbines notably Francis and Kaplan which run full of water and in effect, generate hydrodynamic lift forces to propel the runner blades, extracting thus the pressure energy of inflowing water. Crossflow turbines are widely used on micro hydro sites with typical power outputs from 5 kW up to 100 kW, though they can actually be up to 3 MW in size on the very largest systems, though generally speaking there are better turbine choices for these higher power outputs. They will work on net heads from just 1.75 metres to 200 metres, though there are more appropriate turbine choices for sites with heads above 40 metres. They will work on average annual flows as low as 40 litres/second or up to 5 m3/s, though on the higher flow rates there may be better other turbine types to consider. A cross-flow turbine gets its name from the way the water flows through, or more correctly across the rotor as shown in figure below. The water flows over and under the inlet guide-vane which directs flow to ensure that the water hits the rotor at the correct angle for maximum efficiency. The water then flows over the upper rotor blades, producing a torque on the rotor,
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then through the centre of the rotor and back across the low rotor blades producing more torque on the rotor. Most of the power is extracted by the upper blades (roughly 75%) and the remaining 25% by the lower blades. Obviously the rotor is rotating, so what are the upper blades one moment will be the lower blades the next.

Figure Crossflow turbine in cross-section.

One of the advantages of a crossflow turbine is debris tolerance; leaves etc. that could get pushed into and stuck on the upper blades are washed off by the exiting water on the lower blades, hence the rotor is self cleaning. Also the centrifugal force tends to throw trapped debris outwards, further increasing the self-cleaning capabilities. Crossflow turbines are an impulse turbine, which means that the rotor is spinning in air and is not fully-flooded like in a reaction turbine. The water exits the rotor and falls into the draft tube, which can be many metres long (though not normally more than 1/3 of the total net head across the system). The exiting water fills the draft tube from just below the rotor to the discharge water level. A negative pressure inside the turbine cavity i.e. suction head is created with the air inlet valve on the front turbine casing. The positive water pressure from the upstream side of the rotor is called the pressure head and the sum of the pressure and suction heads equals the net head across the hydro system. The advantage of using a draft tube to maximise the suction head is that the long draft tube moves the main body of the crossflow turbine upwards, away from the discharge water level and
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(hopefully) above the floodwater levels during high flow events. If the main body of the turbine was still likely to get flooded during high flow events it would have to be built into a tanked enclosure. Another major advantage of a crossflow turbine is there wide operating flow range with a high efficiency across the whole range.

CHAPTER 3

METHODOLOGY
PROJECT SELECTION

LITERATURE SURVEY

MICRO-HYDRO STUDY

LABORATORY SETUP STUDY

LAB OPTIMIZATION

TESTING

Fig: Methodology y y y y Firstly, we will survey the present situation and test facilities at the Laboratory at KU. . After that we will study the prevailing testing procedures and laboratory setup. Then, the laboratory will be redesigned. After that, tests will be carried out on the laboratory followed by series of modifications and corresponding tests.

CHAPTER 4

DISCUSSION
4.1 Laboratory
Pressure Regulating Tank

From Source

Reservoir tank

Pump

Pressure Tank

To other test rigs

Re-collection Tank

Turbine

Fig: Diagrammatic representation of the current testing lab The testing lab is as shown above. Water from source is collected in the reservoir tank which is connected to the pressure tank with a valve. The pressure tank is connected to the water transmission pipes and pressure regulating tank. The pressure regulating tank has a valve for controlling the water flow to the tank itself which helps to maintain the desired pressure/head and is connected to the reservoir tank. The turbine setup is connected to the transmission pipes and the water outflow from the turbine is collected in the re-collection tank which is connected to the reservoir tank. Thus, once the water in the reservoir tank reaches to the desired level tests are performed without the loss of water unless there are leakages.

The turbines in the field should be supplied with natural flow of water (Q) under some head (H). However, in the laboratory the flow and head is obtained by a suitable pumping unit which supplies water under a specified pressure. First, the pump is started and the inlet and other valves are opened to ensure supply of water to the turbine. After the setup, the rpm of the propeller shaft and the output of the alternator are measured using tachometer, multimeter and loads of varying power ratings. These data are then used to calculate the efficiency and power output of the turbine.

CHAPTER 5

GANTT CHART

S. No. 1 2 3 4 5

Activities Project Selection Literature Review Laboratory Setup Study Optimization of Laboratory Actual Testing of Turbines

Sept

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

CHAPTER 6

CONCLUSION
Mirco-hydro systems are of great significance in rural Nepal because of its difficult topography and absence of transmission lines. They can be solutions to electrifying rural households. Small communities can be greatly served in the current times where urban areas are facing largespanned loadshedding. After the completion of the project we intend to obtain a fully equipped laboratory with testing facilities for cross-flow turbines of varying range giving reliable, accurate and simple to obtain results. We also hope for developing the skills and knowledge of various engineering procedure for the successful accomplishment of the given job.

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REFERENCES
Khurmi R.S. (1970). The textbook of hydraulics, fluid mechanics and hydraulic machines. S. Chand & Company Ltd.: New Delhi, India.

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