Mini & Micro Hydro Power Generation

EBARA Hatakeyama Memorial Fund Tokyo, Japan

Definitions
Large Scale hydro power generation : Capacity100(MW)
Most of them involve major construction of dams.

Small Scale hydro power generation : Capacity5(MW) per site

Commonly do not involve major construction of dams. Most of them are Run-of-river type . less environment impact

Micro Scale Hydro : Capacity100(kW) per site

Advantages of Mini/Micro Hydro Schemes

1. Renewable and sustainable source of electricity
Hydro energy is a free and a continuously renewable electrical energy source. Hydropower is a completely national resources, without importing any other fuel.

2. Little or no environmental impact

o water pollution or greenhouse gas emissions

3. Technology is proven and reliable

6080(%) efficiency for conversion to electricity Low operating and maintenance costs Full time staff are not required for serving . The system can be integrated with water supply for irrigation and potable systems The working life of the machine is much longer than for diesel generator

Advantages of Mini/Micro Hydro Schemes

(continued)

4. Long life equipment

Existing plants have been in operation for more than half a century and are still providing continuous power as long as water resources are sufficient.

5. Create job opportunities locally

In remote areas, small hydro may have a positive impact on the development of local communities where young people may leave the farms because of low income from farming. The possibility of supplementary income from local electricity production with possibility to start small industry could be the goal for small hydro development in remote areas of developed countries as well as for developing countries. Hence, reduce population migration from remote rural area to urban

Disadvantages of Mini/Micro Hydro Plants

1. Seasonal Water Flow Fluctuation
Flows often vary throughout the year, affecting the availability of water in a certain seasons.

2. Location is everything
Locations where power can be economically exploited are limited. The best sites have a reliable water supply year-round and a large vertical drop in a short distance.

3. Long construction period and higher initial investment

The problem is that the new investors place primary importance on short payback time(Fast Money), where the long life of system is not reflected in the economic analysis of small hydro projects.

Flowchart of Mini Hydro Project Planning

Site Reconnaissance Potential Site Identification of System Layout Confirmation of Design Discharge Selection of the Civil Structures Location Confirmation of the Head Selection of Power Demand Facilities Demand Side

Selection of the Generating System

B A

A
Examination of Demand and Supply Balance

Rough Estimation of the Project Cost

Project Implementation Stage

(Source)Manual for Micro-Hydropower Development/DOE & JICA

Classification of Hydro Plant

Reservoir type Power Station

Conduit type Power Station(Run-of-River type)

Intake Canal Route

Parallel to river system

A system taking water from the up-stream, providing a canal along the river and feeding water to turbine by steep penstock

Short cut system

A system providing a short cut canal at the bend of a river, and feeding water by steep penstock.

Micro Hydro Unit beside Irrigation Weir

A
Irrigation Weir

C G E

F
A B C E F G Intake Lateral By-pass Canal HeadTank GeneratingUnit Tailrace Transmission/Distribution Line

- whenever a weir imposes an excess head relatively to the downstream delivery flow, a micro unit can be envisaged in order to replace a dissipation structure. - along an irrigation canal system, significant difference topographic level can be used and diversion scheme can be implemented out of irrigation period.

Run of River type Micro Hydro Generation System

A Intake

B C

B Lateral By-pass Canal

C Head Tank D Penstock Pipe E Generating Unit G Transmission/Distribution Line

D G E
In order to take the advantage of a local significant difference topographic level created by a weir or a small dam, only a part of stream flow is used to generate power.

Stream Flow type Power Station (Rubber Weir)

Up Stream Rubber type Weir (Inflatable Weir)

Down Stream Trash Rack

Head Race Spillway Stop Log Intake Screen Head Tank Power House Distribution Line Penstock Tail Race

Inflatable Rubber type Weir

Application of Rubber Weir

Plant type : Run-of-River type Max. Flow : 4.6(m3/s) Max. Head : 42.0(m) Max. Output : 1,500(kW) Commissioning : 1991

Intake Facility(Rubber Weir) (Dimensions : 27.4m L x 2.0m H )

Application of Rubber Weir

Plant type : Run-of-River type Max. Flow : 1.8(m3/s) Max. Head : 79.9(m) Max. Output : 1,200(kW) Commissioning : 1997

Intake Facility(Rubber Weir) (Dimensions : 22.0m L x 2.0m H )

Water Intake Facility for Micro Hydro Turbine

Points necessary for Mini Hydro Exploitation

The following items shall be taken into the consideration for Mini Hydro Exploitation. A high rainfall catching area A river or water source with a suitable head of water A easiness of water intake placing in a stream A easiness of transporting the water to the turbine (Easiness of installation of conduit pipe or channel) A easiness of electrical distribution line/grid connection A easiness of returning its water to the main stream

Topography, Rainfall data, Availability of funds

Assessing Hydro Plant Capacity

The amount of energy at a given site can be assessed as ;

P9.8QHe,

e=tggr

where, P : Plant capacity (kW) H : Turbine net head (m) Q : Water flow to turbine (m3/s) e : Turbine generator combined efficiency Mini Hydro : approx. 7585% Micro Hydro : approx. 6575% t : Turbine efficiency(=7590%) g : Generator efficiency(=8596%) gr : Speed increaser efficiency(=9797.5%)

For assessing the power potential, Q and H shall be measured at site.

Classification of Hydro Turbine

Impulse Turbine
Pelton Turbine Cross Flow Turbine Turgo Impulse Turbine

Reaction Turbine

Francis Turbine Propeller Turbine Kaplan Tubular Bulb Centrifugal pump as turbine

Specific Speed vs Applicable Turbine Type

Ns=

NP 0.5 H 1.25

where, N : Turbine Speed (min-1) P : Turbine Output (kW) H : Net Head (m)

Bulb Turbine Pelton Turbine

Turbine Types
Francis Turbine S type Tubular

Cross Flow Turbine

Straflo Turbine

Mini Hydro Turbine Selection Chart

1000

Pelton Francis
m Net Head (m)
100

k 00 50

Cross Flow

W kW 00 30 W k 00 10

W 0k 30 0kW 10

10

Centrifugal Pump as Turbine

Tubular

DL Mixed Flow type Pump as Turbine

1 0.01 0.1 1

Flow (m3/s) m3/sec

kW 50
10 100

Siphon Propeller

Selection Chart for Low Head Turbine

Semi Kaplan

Bulb Turbine

Siphon Propeller S Type Tubular

Comparison of Turbine Performances

Flow Duration Curve

Flow Hydrograph :
A period of 2025 years records is required for planning the Run-of River type Plant.

The most suitable design flow for run-of-river type power station is around 95 day flow. The area below the curve shows the energy of hydro potential in the river

Flow Duration Curve :

A curve of flow versus the percentage of time. This curve is usually the most convenient form for turbine size selection.

95day

An Example of Flow Duration Curves

Flow (m3/s)

Days

Design Flow for Conventional Turbine

(Run-of-River type Mini Hydro Plant)

too small design flow

365days operation available Bypass flow from turbine increased

too large design flow

operating duration shorter (cannot operate in dry season) Bypass flow decreased

Annual Energy Output(kWh) = 365(days) x 24(hrs) x Pg(kW)

Unit Electricity Cost(/kWh)

= Total Construction Cost Annual Energy Output

Flow Duration Curve vs Unit Efficiency

max

In case of maximum efficiency (max) being selected on extreme partial flow point, the runner cavitation at maximum flow shall be carefully studied.

The cost of the Mini Hydro Plant is site specific and may vary widely from scheme to scheme
The cost of the Mini Hydro Plant is site specific and varies greatly depending on the remoteness of the site and physical features of its major components, namely, civil works (including waterways), generating equipment(turbine, generator, control, protection) and electrical transmission/distribution lines. While the cost of generating equipment in the powerhouse is almost a linear function of kWH0.5, the cost of civil works further depend upon the gradient of the waterway(intake to powerhouse). Similarly, the cost of electrical line further depends upon the energy density of the load centers. Therefore, the coat of Mini Hydro Plant installations can vary widely from scheme to scheme. The share of initial civil works component cost may vary from a mere 20% for a relatively high gradient waterway profile and low cost construction to 60% for a relatively low gradient and expensive construction. Therefore, the percentage share of one component on the total initial investment cost would depend upon its own as well as other components construction feature.

Budget for Turbine, Generator and Associated Equipment

(Source) Engineering Manual for Mini Hydro Generation System (NEF, Japan)

Economic Evaluation of H.E.P.

Construction CostkW Construction CostkWh

Construction CostkWh

The most economical Turbine Design Flow

Turbine Design Flow(m3/s)

Construction CostkW

Sizing of Micro Hydro Unit

Utilization of the same two or more units The most of Micro Hydro Unit is not provided the flow control device like conventional hydro turbine.

Minimum Flow

Select the Micro Hydro Unit from Maker Selection Chart by using available minimum flow. The provision of the same two or more units can produce more electric power in plenty of water flow season.

Combination of different units

The power generation will be increased by applying the additional different Micro Hydro Unit, if the surplus flow is smaller than the minimum flow. Minimum Flow

250mm Mixed Flow type Micro Hydro Generating Unit

Siphon Breaker DC Motor Intake Screen

Micro Hydro Generating Unit

Net Head (m) 7.011.8 4.08.8 Flow (m3/s) 0.170.22 0.130.19 Speed (rpm) 1,000 750 Generator Output(kW) 7.315.8 3.29.7

Vacuum Pump Siphon Intake Pipe

HWL

Gross Head : 58m

250Dia. SZ Pump as Turbine Bypass Valve Generator

Features: -The pump for low lift & agriculture usage are applied as turbine. -The generator for diesel engine can be connected to this turbine. reservoir side wall.

Generator Control Panel -No need to provide the large hole on

TWL

Micro Hydro Selection Chart

Pelton Turbine
Features
Suitable for High Head & Small Flow Good partial flow efficiency Height between Nozzle center & Tailwater cannot use as Net Head

Net Head of Pelton Turbine

Construction of Horizontal shaft, Single Jet Pelton

Turbine Runner

Head Tank

h1

H=HGh1h

H
2 Jets Operation

Hst
2 Jets Operation

HG

H : Net Head Hst : Static Head HG : Gross Head hl : Head Losses between penstock inlet and turbine inlet h : Distance between jets center and tailrace

Tail Race

Gross, Static & Net Head for Pelton Turbine

Turbine Efficiency Comparison

Relative Turbine Efficiency (%)

Francis Turbine Pelton 2 Jets Operation Pelton 1 Jet Operation

Turbine Flow Ratio (%)

Turbine Design Flow

Pelton Turbine

Ratings : Net Head : 788(m) Speed : 3,575(min-1)

Flow : 0.0917(m3/s) Output : 619(kW)

Cross Flow Turbine

Features
Suitable for Medium Head & Small Flow Good partial flow efficiency compared with Francis Turbine Height between Runner & Tailwater cannot use as Net Head Light duty equipment
Capacity : 50around 1,000kW Head : 5100m Flow : 0.110(m3/s)

Cross Flow Turbine Construction

Flow

Water Flow in the Casing

1: Runner 2,3: Guide Vane 4: Casing 5: Baffle Plate 6: Inlet Pipe 7: Cover 8: Draft Tube 9: Runner Shaft 10: Bearing Box 11: Shaft Seal 12: Air Valve 13: Silencer 14, 15: Guide Vane Arm 16: Handhole

Under Guide vanes fully closed

Net Head for Cross Flow Turbine

h1

Head Tank

H=HGh1h
H : Net Head Hst : Static Head HG : Gross Head hl : Head Losses between penstock inlet and turbine inlet h : Distance between jets center and tailrace
Tail Race h H Hst HG

Outview of Cross Flow Turbine

Turbine Runner

Cross Flow Turbine Efficiency Comparison

Relative Turbine Efficiency (%)

Maximum efficiency is less than Francis but efficiency at low flow is better.

Francis Turbine

Guide vane opening Guide vane opening Full Guide vane opening

Turbine Flow Ratio (%)

Francis Turbine
Features
Widely used for large, medium and small-scale hydro plant Wide Applicable Head Range : 15300(m) Flow : 0.420(m3/s) for Horizontal shaft Capacity : 20010,000kW for Horizontal shaft Robust Construction Long Life Equipment

Net Head for Reaction Turbines

v2 2 H=HGh1 2gh
Head Tank h1

Hst

H0

H : Net Head Hst : Static Head HG : Gross Head hl : Head Losses between penstock inlet and turbine inlet h : Distance between draft tube outlet and tailrace level V2: Outlet velocity of draft tube

H V22 2g

Tailrace

Francis Turbine Efficiency Comparison

Relative Turbine Efficiency (%)

(Note)Relative Turbine Efficiency 100(%) means the peak efficiency of Ns=around 175m-kW where the highest maximum efficiency is obtained in all Francis turbines

Turbine Flow Ratio (%)

Turbine Design Flow

Outview of Mini Hydro Francis Turbine

1,050kW Francis Turbine Generator

Max. Output : 1,050(kW) Net Head : 65.8(m) Generator Max. Flow : 2.0(m3/s) Rated Speed : 1,000(min-1)

Features
Oil-less, Water-less and Brush-less type Turbine Air-cooled type Turbine Generator Electric motor driven GV actuator

450KVA Francis Turbine Generator

Net Head : 24.6m Flow : 2.23m3/s Speed : 600min-1 Turbine Output : 460kW Features : Oil-less, Water-less & Brush-less equipment Power upped by Scrap & Built

Large scale Francis Turbine

Vertical shaft Francis

Type of turbine : Vertical shaft, Single flow, Francis Net head Maximum flow Rated speed Suction head : 108.2135.7(m) : 250(m3/s) : 250(min-1) : 8.2(m)

Maximum output : 121(MW)

Propeller Turbine
Features Suitable for Low Head : 220m for Mini/Micro Hydro Turbine 660m for Medium & Large Hydro Turbine Good partial flow efficiency for Kaplan type turbine

Kaplan Turbine Runner

Guide vane apparatus

Turbine Runner Vertical shaft Kaplan Turbine

Propeller Turbine Efficiency Comparison

Fixed Runner, Fixed Guide vanes

Relative Turbine Efficiency (%)

Fixed Runner Blades, Variable Guide vanes Variable Runner Blades,Fixed Guide vanes Full Kaplan

Turbine Flow Ratio (%)

Turbine Design Flow

Turbine Applicable Operating Range

Turbine type Pelton Francis Cross Flow Flow Range(Q)
(0.10.2) x QdQQd (0.30.4) x QdQQd (0.20.4) x QdQQd

Head Range(H)
(0.850.9) x HmaxHHmax 0.6 x HmaxHHmax 0.7 x HmaxHHmax

Kaplan & Propeller Turbines :

S type Tubular (Horizontal shaft propeller)

Capacity : 503,000kW Head : 318m Flow : 1.520m3/s Suitable for low head and large discharge plant

Outview of S type Tubular Turbine

Large Scale Kaplan Turbine

Kaplan Turbine

Type of turbine: Vertical shaft, semi spiral,Kaplan Net Head Maximum Flow Rated Speed : 12.314.5(m) : 270.0(m3/s) : 90(min-1)

Maximum Output : 34(MW)

Bulb Turbine

2,400kW Bulb Turbine Casing

Generator for Mini/Micro Hydro Plant

Generator type Synchronous Generator Induction Generator Advantages Disadvantages

available of isolated operation need for complex control and insulated rotor winding adjustable of voltage,frequency & power factor simple construction simple control system to be get excitation from the grid parallel operation only

Items to be considered at Generator Selection : In case of isolated operation, Synchronous generator shall be applied. Rotor & bearing shall be designed to withstand the overspeed at load rejection Estimated Overspeed : Pelton & Francis : approx. 1.82.0 times of rated speed Propeller : approx. 2.53.0 times of rated speed

Construction of Synchronous & Induction Generator

Synchronous Generator

Induction Generator

Governor
Function
o regulate the speed at unit start-up and stop to keep the frequency(speed) of generator under unit isolated operation to control the unit output under unit parallel operation with grid

Mechanical Governor for Mini Hydro Plant

Governor for Micro Hydro Plant

(Electronic Load Control Governor)
to be applied for Micro Hydro Turbine without Flow Control Device Advantages Low cost, No water hammer, Simplified turbine

An Example of Mini Hydro Power Plant in Japan

Mini Hydro Power Station Utilizing Compensation Flow to the River

General Arrangement (Sectional View)

Mini Hydro Power Station

Utilizing Compensation Flow to the River

General Arrangement (Plan View)

Submersible type Turbine Generator

General Arrangement

Submersible Turbine Generator

Net Head : 8.069.12(m) Generator Output : 236(kW) Design Flow : 3.73(m3/s) Voltage : 440(V) Sectional View of Submersible Turbine Generator

Mini Hydro Power Station

Utilizing Compensation Flow to the River

464kW Semi-Kaplan Turbine

Max. Output : 464(kW) Net Head : 7.919.32(m) Max. Flow : 7.63(m3/s) Min. Flow : 3.73(m3/s)

Comparison between Turbine & Pump Performance

Turbine Performance Pump Performance

Semi Kaplan type Turbine

Submersible Pump/Turbine

S type Full Kaplan Turbine Generator

(All Actuators are operated by Electric Motor) Turbine Type : S type Tubular Turbine with Speed Increaser
Turbine

Net Head : 5.45(m) Turbine Flow : 15.0(m3/s)

Speed Increaser

Turbine Output : 694(kW)

Generator Electric Motor Driven Actuator for Runner Blades

Turbine Speed : 200(rpm) Generator Type : Synchronous Generator with AVR Capacity : 670(KVA) Speed : 900(rpm)

540kW Mini Hydro Power Station provided in Irrigation Facilities

Intake Facility Bird Eye View of Power Station

Sectional View

Plane View

135kW Turbine Generator

Inlet Valve Turbine Generator

Side View of Unit

Turbine : Type : Fixed Blades & Guide vanes, Propeller Turbine Ratings : 7.36m x 2.6m3/s x 429(min-1) x 165kW Generator : Type : Horizontal shaft, Induction Generator Ratings : 170kW x 420V x 429(min-1) Unit No. : 4

View from Draft Tube

Turbine Generator Construction

Siphon type Propeller Turbine Generator

Specification:
Turbine :
Type : Vertical Shaft, Tubular type
Generator Runner Blade Controller

Semi Kaplan Turbine Net Head : 3.71.3(m) Max. Flow : 3.7(m3/s)

Siphon Detector

Head race Max WL Tubular Turbine Siphon Intake Min. WL Draft Tube Tailrace

Max. Output : 112(kW)

Generator :
Type : Permanent Magnet type Synchronous Generator Capacity : 110(KVA) Voltage : 400(V) Speed : variable

Sectional View of Hydro Power Station

Sectional View
Intake Gate Generator Intake Gate (Emergency Closing Gate) Machine Hatch Water Head Tank for Cooling Water

Stop Log Control Panels Cooling System for Bearing Water Channel Water Intake Screen Casing Turbine Generator Intake Screen Discharge Valves Draft Tube Tailrace River

Drainage Pit

Existing Headrace

New Headrace

Power Station

Tailrace

Ratings
Turbine Type Max. Output Rated Speed Design Flow Net Head Generator Type Capacity Commissioning Features:
- Guide Vanes & Runner Blades are operated by Electric Motor Driven Actuators. No Oil Hydraulic Pressure System is provided. - Closed circuit water cooling system is applied for bearing oil cooling system.

Kaplan type Tubular Turbine(Bulb type) 2,520kW 138(min-1) 13.0943.0(m3/s) 5.467.0(m) 3 Phase Synchronous Generator 2,520(KVA) March, 2003

Construction of Turbine Generator

1 2 3 4 5

Draft Tube Machine Hatch Outer Casing Inner Casing Stay Vanes

6 7 8 9 10

Generator Stator Generator Rotor Exciter Generator Bearing Runner Servomotor

11 12 13 14 15

Guide Vanes Discharge Ring Runner Blades Runner Boss Runner Cone

16 17 18 19 20

Turbine Bearing
Shaft Mechanical Seal Guide vane Servomotor

Generator Pedestal
Water-Water Cooler for Bearing

Gate Ring

Electric Motor driven Guide Vane Servomotors

Electric Motor Driven Servomotor

(Guide vane Servomotor)

Construction of Electric Motor Driven Servomotor

Schematic Diagram of Electric Motor Driven Servomotor/Governor

Electric Motor Driven Blade Actuator(1/2)

On running ; Actuator Speed n=Generator Speed N

At Runner Blade opening changing; - Actuator Speed nGenerator Speed N : Runner Opening Increased - Actuator Speed nGenerator Speed N : Runner Opening Decreased

End
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