Addis Ababa University

Addis Ababa Institute of Technology

School of Mechanical and Industrial Engineering
(Thermal Engineering Stream)

Proposal on

Manufacturing and Experimental Performance Analysis of a Mico Hydro

Pelton Turbine

By: Kassa Dejene

Advisor: Dr.-Ing. Edessa Dribssa.
Co-advisor : Ato Tilahun Nigussie

Nov 9, 2015
Contents
1
Abstract.......................................................................................................................................................3
1. Introduction.........................................................................................................................................4
2. Problem Statement..............................................................................................................................5
3. Literature Review.................................................................................................................................6
3.1. Theoretical Evidence....................................................................................................................6
3.2. Empirical Evidences.....................................................................................................................7
4. Objectives............................................................................................................................................9
4.1. Main Objective.............................................................................................................................9
4.2. Specific Objectives.......................................................................................................................9
5. Methodology.....................................................................................................................................10
6. Significance of the Research..............................................................................................................11
7. Beneficiary of the Research...............................................................................................................11
8. Expected Out Put...............................................................................................................................11
9. Time Schedule...................................................................................................................................12
10. Budget Schedule............................................................................................................................13
11. Project and Study Location............................................................................................................15
12. References.....................................................................................................................................16

Abstract
Since the industrial revolution has begun in the 18th century, fossil fuel have become the most
vital energy source in human life. However, amount of non-renewable fuel such as gasoline is
2
depleting day by day and will eventually end, more so, these conventional fuels are found only in
some countries which have political constraints, higher transport costs and dependency.

In order to ensure sufficient alternative energy for future, renewable energies should be thought
in mind to a great extent. Ethiopia, is blessed with different kinds of renewable energy resources.

One of the most effective renewable energy, for which Ethiopia is blessed with is hydropower
which uses hydro turbines to generate electricity. Small hydro power turbine can be
manufactured locally that will help in utmost exploitation of the most available renewable energy
resource, water. Having this in mind, localization and manufacturing of these hydro turbines
plays a crucial role economically for the development of the power sector in Ethiopia.




This study aims in manufacturing and performance lab test analysis of one of the hydro turbine
type, peloton turbine, in order to develop a manufacturing manual which will helps in
localization of renewable energy technologies in the hydropower sector with high-quality and
efficiency.

Sand casting, lathe machine, welding machine and drilling machines will be used to manufacture
the turbine based on the design results. Finally laboratory testing results will be evaluated. From
this study, an efficient micro hydro pelton turbine will be expected and working and
manufacturing manual will then be developed.

Key words:-Small Hydro Power, micro hydro pelton turbine, Efficiency, Manufacturing, Manual

1. Introduction
The majority of Ethiopian population (83%) lives in rural areas [1]. Only 17% (2009) of the
population of the country has access to electricity [2]. Currently, very large hydropower plants
are under construction in the country to increase the national power grid coverage as well as to
export some portion of the produced energy to neighbouring countries.
3
Despite the big effort taken by the government of Ethiopia, grid coverage for remote areas in
country is not expected to be fulfilled in near future. Thus off grid power sources play vital role
to provide electricity for remote villages in the country.

The national power supply coverage, which is power generated from mega projects, shall be
consumed by industries, mega cities, towns, and export market for economical and political
leverages. Hence for rural areas that have a renewable energy potential like small hydro power
shall generate power once to supply for it and again to tot up to the national grid in its excess
power.

There are rivers flowing throughout the year Ethiopia with reasonable head and flow rate.
Consequently for some remote locations installing small hydro plants could be the best option as
they are environmentally friendly as well as less expensive option for power generation.

In Ethiopia there are a number of small hydro plants [4]. Most of them use cross flow turbines.
These turbines were supplied by Ethiopian Rural Energy Development & Promotion Centre [4]
from abroad with hard currency. Cross flow turbines are not suitable in location where there is
high head and less flow rate [3].Now days some researches shows that the use of pumps as
turbines for Pico hydro purposes resulting a low efficiency due to its availability and cost
effectiveness wise[5] . For many small-hydro sites, a Micro hydro pelton turbine is the only
option. These turbines have advantage of producing a lot of power from a small unit. In addition
they are reasonably easy to manufacture. Nonetheless, up to date there is no company or
institution engaged in supplying small Micro hydro pelton turbines in Ethiopia.

2. Problem Statement
The knowledge required to design and manufacture Micro hydro pelton turbine is well known
worldwide. But manufacturing and testing this turbine is not yet done in Ethiopia. As a result,
MICRO HYDRO PELTON TURBINE is imported and used for local projects like Gilgel Gibe II
instead of designing and manufacturing the turbine by local companies.

Thus the output of this research will mainly minimize importing and builds local capacity of
manufacturing and testing this machine.

4
3. Literature Review
3.1.Theoretical Evidence
Hydraulic turbine can be defined as a rotary machine, which uses the potential and kinetic energy
of water and converts it into useful mechanical energy. According to the way of energy transfer,
there are two types of hydraulic turbines namely impulse turbines and reaction turbines. In
impulse turbines water coming out of the nozzle at the end of the penstock is made to strike a
series of buckets fitted on the periphery of the runner. Micro hydro pelton turbine is an impulse
turbine. The runner of the Micro hydro pelton turbine consists of double hemispherical cups
fitted on its periphery.

The jet strikes these cups (buckets) at the central dividing edge of the front edge. The central
dividing edge is also called as splitter. The water jet strikes edge of the splitter symmetrically and
equally distributed into the two halves of hemispherical bucket.

5
Theoretically, if the buckets are exactly hemispherical, it will deflect the jet through 180°. Then
the velocity of the water jet leaving the bucket would be opposite in direction to the velocity of
jet entering. Practically, this cannot be achieved because the jet leaving bucket strikes the back of
succeeding bucket and the overall efficiency would decrease. In practice, the angular deflection
of the jet in the bucket is limited to about 165° amount of water discharges from the nozzle is
regulated by a n nozzle.

A deflector is used to control the turbine speed. One or more water be provided with the Micro
hydro pelton turbine depending on the water flow rate and the nozzle capacity.

The Micro hydro pelton turbines have been given increasing interest by the research community
within multiple fields. This is due to the increasing demand for energy on a global basis in
addition to the growing focus on meeting the increasing demand by utilizing renewable energy
resources.

3.2.Empirical Evidences
Edessa Dribssa , Tilahun Nigussie, Bazen Tsegaye[5] analyzed the use of pumps as turbines
and they analyzed that pumps can be used as turbines for Pico hydro up to 2KW installed
capacity because of the non availability of conventional turbines and then resulting cost
effectiveness but at relatively low efficiency 73.75% when compared to conventional micro
hydro pelton turbine which works up to 90% efficiency[6].

Bilal Abdullah Nasir has designed and evaluated a pelton turbine with an efficiency of 97%[7]
and he again explained Properly designed micro-hydro-electric power plant causes minimum
environmental disruption to the river or stream and can coexist with the native ecology[8] which
needs local fabrication.

Ida Bordi Stene briefly explains that The Turbine Testing Laboratory plays an important role in
the education, research and development of the hydro-power industry in Nepal .This test facility,
which can assist in design modifications and performance analysis, will help to produce turbines
that are better equipped to handle the local environment[9].

6
Oliver Paish describes Small hydro offers today one of the most promising energy resources for
long term sustainable development in rural areas of many of the world’s poorer countries.
However, with a few notable exceptions, progress to date has been disappointing relative to both
the potential and the need. Simplified designs of cross flow and pelton turbines were transferred
to local manufacturers and workshops and the technology was soon also adopted in Sri Lanka,
Peru, and Indonesia but no technology transfer of appropriate turbines to local manufacturers in
Ethiopia[10].

CHUKWUNEKE J. L.,ACHEBE C. H.,NWOSU M. C., Sinebe J. E presents the effect of

head and bucket splitter angle on the power output of a pelton turbine (water turbine). Analysis
and simulation using experimental data were carried out on pelton turbine head conditions, high
head and low flow with increased pressure delivered more energy on the bucket splitter which
then generates a force in driving the wheel compared to the result obtained from low head and
high flow operating conditions. A simulation program was developed using MatLab to simulate
the force generated by the bucket as the water jet strikes the existing splitter angle[11].

H.Weber and F. Prillwitz models a hydro power plant and finds practical and user-friendly
mathematical model similar. The models can be practically used[13].

R.G. Simpson, A.A. Williams investgated A fixed geometry propeller turbine with a spiral
casing designed and installed at a field site in Peru. His investigation from field testing showed
the turbine to have an overall mechanical efficiency of 65%. The overall aim of his project was
to use these results and future investigations to develop a manual and method for the design of
pico propeller turbines for local manufacturers indeveloping countries[14].

Amevi Acakpovi, Essel Ben Hagan, Francois Xavier Fifatin investigates a simulation of
hydropower plant including a model of hydraulic turbine, governor and synchronous machine, all
simulated under Matlab software[16].

quinox.org They successfully designed fabricated and constructed a 10KW Micro hydro pelton
turbine in 2013[17].

In the literatures reviewed until now, bringing this technology to developing countries in a cost
effective manner has not been done significantly. Therefore, it has been found that it is more
important to do the manufacturing, and experimental test of a pelton hydro turbine and finally to

7
develop a manufacturing manual that will help in localization of the up to dated micro hydro
pelton turbine technology for hydro power project in Ethiopia.

4. Objectives
4.1. Main Objective
The main objective of this research is to manufacture and experimentally evaluate the
performance of Micro hydro pelton turbine designed by a PhD candidate in the School of
Mechanical and Industrial Engineering department, AAiT, Ato Tilahun Nigussie.

4.2. Specific Objectives

The specific objectives are :-

 Design review of Micro hydro pelton turbine designed by PhD candidate, Ato Tilahun
Nigussie;
 Manufacturing the designed Micro hydro pelton turbine and
 Testing and analysing result of designed Micro hydro pelton turbine.

8
5. Methodology
The main activities in this research entails in, manufacturing, and experimental performance
analysis of micro hydro pelton turbine.

The detail activities in this paper are described below:

 Review the parts and assembly drawings of the Micro hydro pelton turbine designed by a
PhD candidate;
 Plane the manufacturing processes of the turbine (process/ procedure manpower, finance
required estimate, time table, raw material acquisition , etc... );
 Preparing part, assembly and manufacturing drawings for each component of the turbine;
 Manufacture and assemble the turbine;
 Plan/ design the experimental set-up needed to test the performance characteristics of the
turbine;
 Carry out the test;
 Analyze the test data and obtain the performance curve of the machine;
 Compile the manufacturing processes of turbine;
 Compile the total (manufacturing) cost of the turbine and
 Write the complete report of the thesis.

In this proposal CATIA, CFX and SOLIDWORKS software are to be used for Complex
Geometrical Structure Creation, which provides the most complete, and robust solution, tailored
for developing rapidly high-quality mechanical products with the highest productivity in design
changes. In addition, this software will be used for the preparation of manufacturing drawings in
addition to AUTO CAD software.

9
 6. Significance of the Research
The expected outcome of this research is manufacturing and Experimental performance analysis
of micro hydro pelton turbine and manufacturing manual development which is applicable for
local manufacturing of micro hydro pelton turbines which can make a difference in the future in
the energy sector of the nation.

7. Beneficiary of the Research

This research will benefit hydro power manufacturers in the country as the report of this project
can be used as manufacturing guide of these turbines. In addition the overall experience gained
from the conclusion of the project will aid micro, mini and small hydro pelton turbine designers
in decision making process prompting for further research and development. Overall the output
of this project will aid in technology transfer, saving foreign currency and opening of new job
opportunities.

8. Expected Out Put





10
11
 Months

No Activity November December January February March April Ma

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2
Literature review on
1 manufacturing and testing of micro
hydro pelton turbine
Analyzing and review the design,
2
drawings and documents

Preparation of manufacturing
3 drawings and pattern development
for castings

Purchasing and Manufacturing of

4
Parts

5 LAB Testing

12
 6 Analysis of results obtained

Draft report writing and

7
submission

Write up of final report and

8
submission

9. Time Schedule

The project has a 7 Months schedule as shown below in both Gantt chart and in network diagram.

13
 10.Budget Schedule
A= Material cost B= Labor cost
C= A+B
Assembly Material/specifica mac
S.N Part type Qty total unit TOTAL
Type tion unit unit price hine total price
amount price AMOUNT
hour
4 45,000.0 8 46,28
1 Bucket cast iron 1000 Kg 16 1,280.00
5.00 0 0.00 0.00
pattern development 3 150.0 15 3,87
2 Bucket Aluminum, sand 5 Kg 24 3,720.00
and molding 0.00 0 5.00 0.00
Emery cloths and 15 450.0 45
3 3 M2 -
sand papers 0.00 0 0.00
steel, 3 661.7 5 1,04
4 Shaft 22.1 Kg 7 385.00
Ф60mm,L=700mm 0.00 1 5.00 6.71
1,200 2,400.0 2,40
5 Bearing with housing 2 pcs -
.00 0 0.00
steel plate, 20 200.0 4 36
6 Hub 1 pcs 4 160.00
Ф100mm 0.00 0 0.00 0.00
steel plate, 7 147.0 7 46
7 Flange 2 pcs 4 316.00
Ф200mm,t=10mm 3.52 5 9.00 3.05
45 450.0 3 66
8 Shaft and Pulley Aluminum 1 pcs 6 210.00
0.00 0 5.00 0.00
hub
6 120.0 12
9 Belt B-type 2 pcs -
0.00 0 0.00
Bolt and Nut with 1 480.0 48
10 40 pcs -
Washer 2.00 0 0.00
Bearing with housing 25 500.0 3 53
2 pcs 1 35.00
mounting buckets 0.00 0 5.00 5.00
17
8 170.0
11 O-ring 2 pcs - 0.00
5.00 0

14
 87 2,198.0 15 2,49
12 sheet metal 2x1m, 2mm 2.5 pcs 2 300.00
9.20 0 0.00 8.00
80x80x6mm, 1,424 2,848.0 22 3,74
13 Angle Iron 2 berga 4 900.00
6meter .00 0 5.00 8.00
Bolt and Nut with 1 1,045.0 1,04
14 Casing 55 pcs -
Washer 9.00 0 5.00
Flanges for distributor 8 170.0 3 23
2 pcs 2 60.00
connection 5.00 0 0.00 0.00
38 760.0 12 1,01
15 clear glass 6mm thick 2 M2 2 250.00
0.00 0 5.00 0.00
Generator 17,50 17,500.0 17,50
16 1 set -
rent 0.00 0 0.00
25,00 25,000.0 12 27,62
17 Modification of Existing Laboratory Test Bench 1 set 21 2,625.00
0.00 0 5.00 5.00
8,500 8,500.0 8,50
18 Laboratory testing tools and measuring equipments 1 set -
.00 0 0.00
7,000 7,000.0 7,00
19 Other materials and Stationary items 1 set -
.00 0 0.00
SUM 115,749.75 10,241.00 125,990.75

15
11.Project and Study Location

Addis Ababa Institute of Technology(AAiT), Addis Ababa University, Ethiopia

16
12. References
1. http://data.worldbank.org/indicator/SP.URB.TOTL.IN.ZS
2. http://data.worldbank.org/indicator/EG.ELC.ACCS.ZS/countries/ET?display=graph
3. The Micro-hydro pelton turbine Manual: Design, Manufacture and Installation for Small-
scale Hydropower,Jeremy Thake, ITDG Publishing, 2000.
4. Micro-Hydropower Under Ethiopian Conditions,ZelalemHailu, School of Graduate
StudiesAddis Ababa University, 1993
5. PERFORMANCE ANALYSIS OF CENTRIFUGAL PUMP OPERATING AS TURBINE
FOR IDENTIFIED MICRO/PICO HYDRO SITE OF ETHIOPIA, Edessa Dribssa , Tilahun
Nigussie, Bazen Tsegaye, International Journal of Engineering Research and General Science
Volume 3, Issue 3, May-June, 2015, ISSN 2091-2730
6. pelton turbine design of Gilgel Gibe II, Reiner Mack, Voith Siemens Hydro’s
Product,2006
7. DESIGN OF HIGH EFFICIENCY MICRO HYDRO PELTON TURBINE FOR
MICROHYDRO POWER PLANT, Bilal Abdullah Nasir, INTERNATIONAL JOURNAL OF
ELECTRICAL ENGINEERING & TECHNOLOGY (IJEET), Volume 4, Issue 1, January-
February (2013), pp. 171-183
8. Design of Micro - Hydro - Electric Power Station, Bilal Abdullah Nasir, International
Journal of Engineering and Advanced Technology (IJEAT)ISSN: 2249 – 8958, Volume-2, Issue-
5, June 2013
9. Design of a Pelton Model Test Rig at Kathmandu University, Ida Bordi Stene, Master’s
thesis, Norwegian University of Science and Technology, Department of Energy and Process
Engineering, June 2014
10. Small hydro power: technology and current status, Oliver Paish, Renewable and
Sustainable Energy Reviews 6 (2002) 537–556
11. ANALYSIS AND SIMULATION ON EFFECT OF HEAD AND BUCKET SPLITTER
ANGLE ON THE POWER OUTPUT OF A MICRO HYDRO PELTON TURBINE,
CHUKWUNEKE J. L.,ACHEBE C. H.,NWOSU M. C., Sinebe J. E. ,International Journal of
Engineering and Applied Sciences, Aug. 2014. Vol. 5. No. 03
12. Dynamic Modeling of Micro-Turbine Generation Systems Using Matlab/Simulink, S. E.
Abdollahi and A. Vahedi, Department of Electrical Engineering Iran University of Science and
Technology Narmak, Tehran (Iran)
13. Simulation model of the hydro power plants in Macedonia and Yugoslavia, H.Weber and
F. Prillwitz,2003IEEE Bologna Power Tech June23-26, 2003

17
14. Application of computational fluid dynamics to the design of pico propeller turbines,
R.G. Simpson, A.A. Williams, Nottingham Trent University for Proceedings of the International
Conference on Renewable Energy for Developing Countries – 2006
15. MODELLING OF MICRO HYDROELECTRIC SYSTEM DESIGN , NOOR AZLIZA
BT IBRAHIM, MSc Thesis, Faculty of Electrical and Electronic Engineering ,University Tun
Hussein Onn Malaysia, JULY 2012
16. Review of Hydropower Plant Models, Amevi Acakpovi, Essel Ben Hagan, Francois
Xavier Fifatin, International Journal of Computer Applications (0975 – 8887) Volume 108 – No
18, December 2014
17. Design and Construction of a 10KW Micro hydro pelton turbine, Evan Lawson,
www.e.quinox.org, info@e.quinox.org

Submitted by:
Kassa Dejene ______________ _______________
Student Signature Date

18
Approved by:

Dr. Ing Edessa Dribsa ______________ _______________

Advisor Signature Date

Ato Tilahun Nigussie _______________ _______________

Co- Advisor Signature Date

Dr. Ing Demis Alemu _______________ _______________

Chairman, Dept.’s Signature Date
Graduate Committee

______________________ _______________ ________________

Chairman, Faculty’s Signature Date
Graduate Committee

19