CHAPTER 3

METHODOLOGY

This chapter discusses the processes and presents the general sequential flow

process followed in order to attain the objective of the project which is to design and

install a picohydrosystem at Brgy. Tanato, Balanga City, Bataan.

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 Fig. 3.1 Overall Project Flow

3.1 Planning

3.1.1 Gantt Chart

This Gantt chart in Table 3.1 shows the graphical representation of the

scheduled tasks completing the project study for the semester.

Table 3.1 Gantt Chart

Month February March April May

Week 1 2 3 4 1 2 3 4 1 2 3 4 1

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 Planning and
designing

Canvasing of
Materials

Purchasing of
Components

Assembly of
Prototype

Trouble
Shooting

Testing

Data Collection

Documentation

3.1.2 System Planning

The researchers have planned and studied the overall aspects of pico

hydroelectric system. Aspects such as the construction, operation, reliability,

efficiency, robustness, cost and environmental impacts have all taken part in

order to attain the objective of the pico hydroelectric system.

3.2 Site Selection and Evaluation

The researchers has initially selected potential river sites for the installation of

pico hydroelectric system specifically, Tanato River and Damulog River as shown in

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Fig. 3.2. Water flow rate, water level and the need for the application of electrical power

have been the criteria for evaluating which among the two is the ideal site for the said

system. Water flow rate is measured using float method. Referring to the criteria,

Tanato River has been proved and chosen to be more preferable rather than the latter as

shown in Table 3.1.

Fig. 3.2 Site Visitation in Tanato and Damulog River

Table 3.2 River Analysis

Site Flow Rate

Damulog River 0.031
Tanato River 0.054

Fig. 3.3 Site Location – Tanato River Park

The site is located at Barangay Tanato, Balanga City, Bataan as shown in Fig.

3.3. It is approximately 20-minute travel from the nearby City Proper of Balanga. It is

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considered as upland barangay thus it is known for its contribution in agriculture in the

province. The picohydro system will be installed at “Tanato River”, which is the

existing river located at the said barangay.

3.3 Selection of Component Criteria

3.3.1 Selection of Turbine

Due to the concern in efficiency, no head and low flow characteristics

of the river as well as to minimize the complexity of the system, an undershot

waterwheel will be used in the pico hydroelectric system.

3.3.2 Selection of Penstock

Due to having a variety of cross sections available, having a little of

installation area and having less bents for much minimal losses and more

efficient flow of water as well as its energy , an open-channel penstock makes

much more ideal for a pico hydroelectric system rather than the enclosed pipe

type.

3.3.3 Selection of Generator

Due to its non-grid dependence, ability to run in isolated conditions,

operation at a speed directly linked to frequency when not connected to the grid,

ease in load power factor accommodation and its ease in regulating output

frequency, a synchronous generator or commonly called as alternator with a

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non-salient pole type rotor is used in the pico hydroelectric system. The non-

salient pole type rotor has mechanical robustness and gives noiseless operation

at very high speed (1500-3000 rpm).

3.3.4 Selection of Drive System

Due to its narrow-size, durability, speed precision and power

transmission efficiency caused by far less frictional loss, a chain-sprocket

system is much desirable to be used in pico hydroelectric systems as compared

to a pulley system.

3.3.5 Selection of Battery

Due to continuous usage, batteries that are required in pico hydroelectric

systems must be rechargeable batteries. Moreover, batteries used in the pico

hydroelectric systems are deep-cycle batteries/deep-discharge. This type of

battery delivers nearly all the energy stored, and be recharged fully and expected

to deliver a majority of their capacity many times in their lives. In this case, a

valve-regulated lead acid batteries will be used because of its less maintenance

characteristics.

3.3.5.1 Load Modeling and Battery Sizing

To arrive at the size of the components that will be used in the

system, the first thing to do is to list down all loads consuming the

battery. An easy way in representing all the loads involve is to tabulate

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all its parameters. This can help ease the computation of the parameters

included, namely quantity, power, voltage, current, hours (day), hours

(night), and ampere-hours. The tabulation of loads of the system is

shown on Table 3.1.

Table 3.3 Tabulation of Loads

Rated Operating
Load Qty Voltage Current Capacity
Power Hours
LED
8 19W 220V 86mA 12 hrs 8.256Ah
Lamps

The next thing to do is to find out the autonomy days. This

determines how long the battery will last without charging with

continuous usage of the load. The system was designed to have 5 days

of autonomy days due to extreme dry and wet seasons. Next,

computation for sizing follows:

Ahuse = Ahload x Autonomy Days = 8.256 x 5 = 41.28Ah

Equation 3.1

Ahuse is the total charge used by the loads after five days of

operation. If this value is multiplied by the system voltage, then the total

energy used by the loads is equivalent to 9081.6 WH based from

Equation 3.2:

Total Energy = Ahuse x Vsystem = 41.28Ah x 220V = 9081.6 Wh

Equation 3.2

The idea here is that the battery must have this amount of energy,

but batteries are not designed to discharge all energy stored as this

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 reduces the lifespan of the battery. To overcome full discharging,

manufacturers of batteries specify the depth of discharge or DOD in

terms of percentage. The researchers chose to discharge the battery up

to 75%; using this value, the size of battery can be finally computed. The

computation is shown in Equation 3.3:

Ahtotal = Ahuse / DOD = 41.28Ah / 0.75 = 55.04Ah

Equation 3.3

3.3.6 Selection of Lamps

Due to its directional light emission, compact profile, superior optical

control, energy efficiency, breakage resistance, reduced maintenance and long

life characteristics as compared to other types, LED lamps made itself

preferable for street illumination and as an application for the generated power

of the pico hydroelectric system.

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3.4 Design and Fabrication of Components

Fig. 3.4 Flowchart of Design and Fabrication

3.4.1 Design of Pico Hydroelectric System

In order to visualize the design of the pico hydroelectric system, a 3D

model as shown in Figure 3.5 shows the initial and proposed design of the said

system. Figure 3.6 shows the designed operational diagram of the system.

Fig. 3.5 Design of Pico Hydro

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 Fig. 3.6 Basic Operational Diagram

3.4.2 Canvassing and Procurement of Materials and Components

The materials and components to be used in the system were determined,

assessed and estimated based mainly on their individual cost, availability,

function and quality. Some materials and components were subjected to

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purchasing in local hardwares and commercial enterprises. On the other hand,

some materials were subjected to improvisation at home. The following are the

materials procured for the system.

Fig. 3.7 Suzuki Daihatsu Alternator

Fig. 3.8 Sealed-ball Bearing

Fig. 3.9 60Ah Lead Acid Battery

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 Fig. 3.10 12Vdc to 220Vac Inverter

Fig. 3.11 12V Automatic Voltage Regulator

Fig. 3.12 LED Lamps

3.4.3 Fabrication of Turbine

In order to visualize the design of the undershot water wheel/turbine, a

3D model was made based from the dimensions set. Fig. 3.13 shows the

isometric view of the waterwheel. Fig. 3.14 shows the dimesions of the

waterwheel.

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 Figure 3.13 Isometric View of the Turbine
The shaft is made up of solid threaded metal rod while the braces are

made up of flat bars of metal. Since the wheel/turbine will be subjected to water,

a primer is used to coat the braces of the turbine. In this way, it will not readily

corrode, rust or stain with water like ordinary steel. Galvanized steel sheet is

used for the fabrication of the blades for the same reason.

Figure 3.14 Water Wheel Dimensions

The water wheel is initially fabricated per component particularly the

blades as well as the braces. Together with the shaft bought and cut, the

components were later welded as one. In this way, the turbine can be aligned

properly to minimize errors as designed in the system.

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 Fig. 3.15 Fabrication of Undershot Water Wheel

Fig. 3.16 Undershot Waterwheel

3.4.4 Fabrication of Penstock and Inlet

In order to visualize the design of the penstock, as shown in Figure 3.16,

a 3D model was made based from the dimensions set. The penstock and inlet

were primarily made from galvanized steel sheet. Fig. 3.17 shows the

dimensions of the said penstock and inlet.

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Fig. 3.17 Isometric View of the Penstock and Inlet

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Fig. 3.18 Penstock and Inlet Dimensions

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 The support is the first one to be fabricated and welded. Penstock

supports are installed to constrain the movement of the penstock. It is made up

of angular bars that was cut lengthwise and pieces of reinforced bars.

Like in the construction of the turbine, together with the metal sheets

bought and cut, the components were later welded as one. For the same reason,

this enables the penstock to be aligned properly to minimize errors as designed

in the system.

Fig. 3.19 Fabrication of Penstock and Inlet

Fig. 3.20 Penstock with Inlet

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 3.4.5 Fabrication of Powerhouse and Gate

After the fabrication of penstock, the fabrication of powerhouse and gate

had immediately followed. The said components were basically made from

scrap materials. The design of the components is dependent on the dimensions

of the penstock itself.

3.4.6 Construction of Drive System

The construction of the chain-sprocket system is calculated and based

on the figure. The speed ratio of the system is dependent on the diameter and

the number of teeth of the sprocket and the length of the chain. Fig. 3.21 shows

the dimensions of the said chain and sprocket.

Fig. 3.21 Drive System Dimensions

3.5 Component and Circuit Assembly

3.5.1 Circuit Assembly

The alternator, automatic voltage regulator, battery and the inverter are

to be connected in the following manner. The circuit must take note of proper

sizing of wire as well as correct device terminal connections as shown in Fig.

3.22.

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 Fig. 3.22 Alternator to Inverter Circuit

3.5.2 Component Assembly

After the fabrication, procurement and laying out of individual

components, the assembly of all the individual components immediately

followed. First, the inlet was connected unto the penstock. This was done by

putting 3 hinges in between and securing those using bolts and nuts. Next, the

turbine was put near the lowest level of the penstock. It was connected via

pillow block and was assured that none of them are misaligned and no loose

ends are present. The turbine was assured that it is properly aligned with about

1 cm space in between the penstock floor and the blades. Likewise, the turbine

was also assured not to come in contact with the penstock side walls. Then, the

powerhouse containing the alternator, automatic voltage regulator, battery as

well as the inverter was properly fixed and set out keeping in mind that the

alternator must also come aligned with the system design. Afterwards, the

chains and sprockets were put into place connecting the turbine shaft and the

alternator’s rotor. Finally, the electrical components including the loads of the

system are properly connected and verified to be operational.

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3.6 Installation

3.6.1. System Installation

The installation begun with the transportation of the pico-hydroelectric

system to the target site. The system was drawn carefully from the top of the

river. Upon submerging, the gate was held close while the junction in between

the penstock and the inlet was placed in between the boulders enough to take a

relatively enough flowing water. The hinged inlet was adjusted at 45 degrees

below the higher horizontal where the maximum flow of said water can be

obtained. On the other hand, the penstock was placed 15 degrees directly above

the lower waters. Fig. 3.23 shows the proper installation of pico hydroelectric

system.

Fig. 3.23 Installation of Pico Hydroelectric System

3.6.2 Street Light Installation

The lighting system was proposed to be installed about 20 meters from

the pico hydroelectric system. The poles and luminaires are designed to be 7

meters apart from each other with a mounting height of 3.89 meters in each and

every pole as shown in Fig. 3.24 and Fig. 3.25.

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 Fig. 3.24 Dimensions of Proposed Installation of Street Lightings

Fig. 3.25 Street Lightings

3.7 Testing and Data Gathering

After the group was done installing all components of the pico hydroelectric

system, the testing and data gathering of the system immediately followed. The group

first prepared the loads that will be supplied by the electricity that will be produced by

the battery through the generator. Then the group opened the inlet gate in order for the

water to pass. When the turbine was already rotating and driving the generator, the

following testing and data gathering methods constantly followed. Fig. 3.26 shows the

flow of the whole testing and data gathering procedure.

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 Fig. 3.26 Testing and Data Gathering Flowchart

3.7.1 Flow Rate Measurement

The measurement method that the researchers used in order to get the

flow rate of the water was float method. This method can be used to measure

the rate of flow passing a point in an open channel by multiplying the cross-

sectional area of water by the average velocity of the water. Normally, the cross-

sectional area can be determined by direct measurement of the channel

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dimensions. On the other hand, the velocity can be estimated by timing the

passage of a small float through a measured length of channel. The dimensions

of the channel are measured using a meter stick and a hollow-sphere ball is used

as the float for the calculation of the said velocity as shown in Fig. 3.27.

Fig. 3.27 Flow Rate Measurement

3.7.2 Turbine and Generator Speed Measurement

The measurement of the speed of the turbine and the generator was done

using a tachometer. By means of a reflective strip, the tachometer, placed

perpendicular to where the strip is located, can measure the speed of the both

rotating devices in revolutions per minute as shown in Fig. 3.28.

Fig. 3.28 Speed Measurement

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3.7.3 Alternator and Load Current Measurement

The measurement of the current flowing from the generator and to the

load was done using a multitester. The probes of the tester were placed in series

between the two terminals where generator DC current can be measured. On the

other hand, the conductor connecting the inverter and the parallel loads are

clamped to measure the AC current that flows through the said loads as shown

in Fig. 3.29.

Fig. 3.29 Current Measurement

3.7.4 Alternator and Load Voltage Measurement

The measurement of the voltage induced by the generator and those on

the load was both done using a multitester. The probes of the tester were placed

in parallel between the two terminals where generator DC voltage can be

measured and also parallel to where the loads are to measure the AC voltage as

shown in Fig. 3.30.

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 Fig. 3.30 Voltage Measurement

3.7.5 Illumination Measurement

In measuring the illumination of the proposed street lights, the

researchers used the point to point method. This is a method used to calculate

the horizontal illuminance on a work plane within a space, as well as its

uniformity. Only the direct illumination from the luminaires to the work plane is

taken into account. The illuminance at each point is determined by applying

the inverse square law and the cosine law to the intensity data for each luminaire

under the given angle. The illumination from the different point sources tends

to add. In this way, the total illumination at a given point on the work plane can

be calculated.

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