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Module 4.

3 MicroMicro-Hydro

4.3.1 Designing
Tokyo Electric Power Co. (TEPCO)

1-Nov-05 (12:01)

Workshop on Renewable Energies


November 14-25, 2005
Nadi, Republic of the Fiji Islands

Contents
Design (Civil Structure)
9 Weir, Intake, Settling basin, Headrace, Forebay, Penstock,
Powerhouse

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Head Loss Calculation


Design (Electrical and Mechanical Equipment)
9 Inlet valve, Water turbine, Turbine governor, Power
transmission facility, Generator, Control panels, Switchgear

1-Nov-05 (12:01)
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Civil Structure: Weir


Types of Weir

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

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Characteristic of Weir
Type

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Outline

Concrete gravity dam


Entire body is composed
of concrete.

Floating concrete dam


Entire body is composed
of concrete.
Longer dam epron
cut-off

Foundation

Bedrock

Gravel

River condition

Not governed by gradient,


discharge or level of
sediment load

Not governed by gradient,


discharge or level of
sediment load

Intake efficiency

High

High

Concrete gravity dam

Floating concrete dam

Earth dam
Main material is earth.
Riprap and core wall

From earth to bedrock


Gentle flow and easy to
deal with flooding
High

Earth dam

Cut-off

Longer epron

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Characteristic of Weir
Rock fill dam

Type

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Outline

Wet masonry dam

Main material is gravel.


Core wall

Gabion dam

Gravel is filled with mortal


etc.

Gravel is wrapped by
metal net.

Foundation

From earth to bedrock

From earth to bedrock

From earth to bedrock

River condition

In case that earth dam


could be washed away by
normal river flow.

Not governed by gradient,


discharge or level of
sediment load.

In case that rock fill dam


could be washed away by
normal river flow.

Intake efficiency

Low

High

Low

Rock fill dam

Wet masonry dam

Gabion dam

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Characteristic of Weir
Concrete reinforced
gabion dam

Outline

Surface of gabion dam is


reinforced with concrete.

Foundation
River condition
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Bush wood dam

Type

Intake efficiency

From earth to bedrock


In case that metal net
could be damaged by
strong river flow.
High

Concrete reinforced gabion dam

Wooden frame with gravel


dam

Main material is local


bush wood.

Wooden frame is filled


with gravel.

From earth to bedrock


Gentle river flow

Fair

Bush wood dam

From earth to bedrock


In case that rock fill dam
could be washed away by
normal river flow.
Low

Wooden frame with gravel dam

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Concerns to be addressed in Weir Designing

Location of weir site


9

Perpendicular to river direction

Topographical & geological conditions

Easy access

Structural Stability

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Sedimentation
9

Easy flushing

Existing landslide, debris, erosion, drift woods etc.

Influence on head acquisition


9

Fall resistance, Sliding resistance & Soil bearing capacity against resultant
external force (weir own weight, water pressure, sedimentation weight, earth
quake & up lift)

Relationship between construction cost & usable head

Backwater effect
9

Influence on upstream area during flooding

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Civil Structure: Intake


Type of Intake

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Side intake
9

Typical intake

Perpendicular to river direction

Tyrolean intake
9

Along the weir

Simple structure

Affected by sedimentation
during flooding

More maintenance required

Side Intake

Tyrolean Intake
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Civil Structure: Settling Basin


Function
9 All the suspended materials that could
adversary affect turbine should be removed.
Dam
Intake

Spillway

Stoplog

9 Minimum diameter of suspended materials


(depend on turbine specification; 0.5
1.0mm)
9 Marginal settling speed (about 0.1m/s)
9 Flow velocity in settling basin (about 0.3m/s)
9 Length & wide

Flushing gate

Headrace

1.0

Conduit section

2.0

Settling section

Widening section

Bsp

hsp+15cm

10 15

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Specification to be decided

Intake

hi

h0

hs

ic=1/201/30

bi

Stoplog

Sediment Pit

Flushing gate

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Civil structure: Headrace


Function
9 Conveys water from intake to forebay

Specification to be decided

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9
9
9
9

Structure type (Open channel)


Longitudinal slope (1/50 1/500)
Cross section (flow capacity)
Material to be used

Flow capacity calculation


Qd=AR2/3SL1/2 n
where,
Qd: Flow capacity (design discharge: m3/s )
A: Cross-sectional area
R: R = A/P
P: Length of wet sides
A
SL: Longitudinal slope
n: Coefficient of roughness

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Characteristic of Headrace

Advantage

Disadvantage
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Lined channel
(Rock & stone)

Simple earth
channel

Type

9 Easy construction
9 Inexpensive
9 Easy repair

9
9
9
9

9 Risk of scouring &


collapse
9 Not applicable to
high permeable
ground
9 Difficult to remove
sedimentation

9 Not applicable to
high permeable
ground

n = 0.030

Easy construction
Local material
Scouring resistance
Easy repair

Concrete channel

9 Local material
9 Scouring resistance
9 Applicable to
permeable ground
9 Easy construction

9 Great flexibility of
cross section
design

9 Relatively expensive
9 More man power

9 Not applicable to
small diameter
9 Long construction
period

n = 0.020

n = 0.025

Simple earth
channel

Wet masonry
channel

Lined channel
(Rock and stone)

n = 0.015

Wet masonry
channel

Concrete channel

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Characteristic of Headrace

Advantage

Disadvantage
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Box culvert channel

Wood fenced channel

Type

9 Inexpensive
9 Flexible to minor ground
deformation

9
9
9
9

9 Not applicable to big


diameter
9 Easy to decay

9 Heavy weight
9 High transportation cost

n = 0.015

Wooded-fenced channel

Easy construction
Short construction period
Applicable to small diameter
Flexible to cross section
figure

n = 0.015

Box culvert channel

Hume pipe channel


9 Easy construction
9 Short construction period
9 High resistance to external
pressure
9 Applicable to small diameter
9 Heavy weight
9 High transportation cost

n = 0.015

Closed pipe (Hume pipe, steel pipe)

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Civil Structure: Forebay


Function
9

Regulates discharge fluctuation


difference between penstock &
headrace due to load fluctuation.
Final settling basin

Screen

Spillway

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Specification to be decided
9
9

Water storage capacity


Layout & dimension of each facility

Attached Structure
9
9
9
9

Spillway
Screen
Regulating gate
Sluice gate

Headrace
Spillway
Penstock

Headrace

Screen
Headrace

Penstock

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Civil Structure: Penstock


Function
9 Convey water under pressure from
forebay to turbine

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Specification to be decided
9 Route (Slope, geological conditions
etc)
9 Material to be used
9 Diameter
- Construction cost
- Electricity generation decrease due
to loss at penstock
- Durability (Life time, O&M cost)

9 Thickness
- Water pressure, own weight, water
weight, other external force (earth
quake etc.)

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Powerhouse
Powerhouse
z

Function:
Provides shelter for the electro-mechanical equipment (turbine,
generator, control panels, etc.)

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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.

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Foundation for Impulse Turbine


a. Foundation for Impulse Turbine
The figures shows the foundation for the cross flow turbine. There
is a space between center level of the runner and the tailwater level

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hc ={

30 50cm

1 .1 Q d 2
9 .8

1/ 3

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

Space
(atmosphere pressure)

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

20cm

b o : d ep end s o n Q d and H e

2 0 cm
b

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Foundation for Reaction Turbine


b. Foundation for Reaction Turbine
The below figures show the foundation for the Francis turbine. The
outlet level of the draft tube is under the level of tailwater
A

d3

ThisHshead
is also
effectively utilized
depens on characteristic
of turbine

Filled with water


In the draft tube

30 50cm

20cm

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hc={
Hs

1.1Qd
9.8

1/ 3

Flood Water Level(Maximum)

1.15 d3
H L3
(see Ref.53)

2 3
1.5d3

A
Section A-A

1.5d3

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Effective Head
Effective Head (Net head) :
= The total head actually acting on the turbine
= Gross head Head loss
He = Hg (HL1 + HL2 + HL3)
where, He: Effective head
Hg: Gross head
HL1: Loss from intake to forebay
HL2: Loss at penstock
HL3: Loss at tailrace and draft tube
Intake

Headrace
Settling Basin

HL1
HL2

Forebay
Penstock
Powerhouse

He

H Hg

HL3
Tailrace

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Calculation of Head Loss


The head loss at the penstock (HL2) can be calculated by
the following equations.
HL2 = hf + he + hv + ho
where,

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hf: Frictional loss at penstock


he: Inlet loss
hv: Valve loss
ho: Other losses (Bend losses, loss on changes in crosssectional area and others)

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<Reference > Head Loss at Penstock


(1) Frictional loss
Frictional loss (hf) is the biggest of the losses at penstock.
hf = f (Lp/Dp ) Vp2/2g

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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
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<Reference > Head Loss at Penstock


(2) Inlet Loss

where,

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(3) Valve Loss

where,

hi = fe Vp2/2g
hi: 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)

(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)

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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. Generator:
Generates the electricity by the driving force from the turbine
4. Driving facility:
Transmits the rotation power of the turbine to the generator
5. Control facility of turbine and generator:
Controls the speed, output of the unit.
6. Switchgear / transformer :
Controls the electric power and increases the voltage of transmission
lines, if required
7. Control panels:
Controls and protects the above facilities for safe operation.
Note: Items 5, 6 & 7 above may sometimes be combined in one panel.

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1. Inlet Valve

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Design of E/M Equipment

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Design for E/M Equipment


2. Water Turbine
Types:
z

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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
Impulse
Reaction

Head
High

Medium

Low

Pelton
Turgo

Crossflow
Turgo

Crossflow

Fransis
Pump-as-Turbine

Propeller
Kaplan

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Pelton Turbine
Acting water jet emitted from the nozzle to the bucket of runner
Good characteristics for discharge change
- Discharge: Small (0.2 3 m3/s)
- Head: High head (75 400m)

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Design of E/M Equipment

Design of E/M Equipment


Pelton Turbine

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Design of E/M Equipment


Cross-Flow Turbine
Arc shape runner blades are welded on the both side of iron plate discs
Easy manufacturing and simple structure
- Discharge: Small (0.1 10 m3/s)
- Head: Low, middle head (2 200 m)

Water
CrossCross-Flow W/T

Guide Vane

Design of E/M Equipment


Cross-Flow Turbine

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Francis Turbine

Wide ranging utilization from various head and output


Simple structure
- Discharge: Various (0.4 20 m3/s)
- Head: Low to high (15 300 m)

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Design of E/M Equipment

Design of E/M Equipment


Francis Turbine

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15

Reverse Pump Turbine (Pump as Turbine)

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Design of E/M Equipment

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Design of E/M Equipment


Tubular Turbine

Tubular type(Cylinder type) propeller turbine


Package type is remarked recently
- Discharge: Various (1.5 40 m3/s)
- Head: low head (3 20m)

Timing Belt

Generator
Draft Tube

Guide Vane Propeller Runner


(Wicket Gate)
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Design of E/M Equipment

Tubular Turbine

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Design of E/M Equipment

Pico Hydro

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Design of E/M Equipment


Flow chart of designing hydro turbine
Power plant H,Q
Number of units
Turbine type selection by
the selection chart

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Range of Ns
(m-kW)

Turbine type

Ns limit

Pelton

8 25

Francis

50 350

Diagonal flow

100 350

Propeller

200 900

Tubular

N limit calculation from the


Ns limit

More than 500

Specific speed:
Ns[m-kW] = N

P1/2
H5/4

N (min-1)

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Design of E/M Equipment


Selection of turbine type

i.e.: H = 25m, Q = 0.45m3/s


3
(82ft)

Cross Flow

1000

(3,280)

or Horizontal Francis

(m, ft)

Effective Head

Horizontal Pelton

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(15.88ft /s)

Vertical Francis

100

(328)

10

(32.8)

Cross Flow
Horizontal Francis

(3.28)

1
0.01
(0.3529)

0.1
(3.529)

Horizontal Propeller

1
(35.29)

10
(352.9)
3
3
Water Discharge (m /s, ft /s)

100
(3,529)

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Design of E/M Equipment


3. Generator
z

Synchronous:

Asynchronous (induction):

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Independent exciter rotor, applicable for both isolated and existing


power networks
No exciter rotor is usually applicable in networks with other power
sources. In isolated networks, it must be connected to capacitors to
generate electricity.

Generator output:

Pg (kVA) = (9.8 x H x Q x )/pf

Where
Pg: Capacity (kVA)
H : Net head (m)
Q: Rated discharge (m3/s)
: Combined efficiency of turbine & generator etc (%)
pf: Power factor ( %)

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Design of E/M Equipment


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 (min-1) = 120 x f/P
where, P : Number of poles
f : Frequency (Hz)
N0 : Rated rotational speed (min-1)
For induction generators:
N (min-1) = (1-S) x N0
where, N : Actual speed of induction generator (min)

S : Slip (normally S= -0.02)


N0 : Rated rotational speed (min-1)
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Standard rated speeds and number of poles for synchronous


generators
No. of poles

50 Hz

60 Hz

1500

1800

1000

1200

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Design of E/M Equipment

750

900

10

600

720

12

500

600

14

429

514

16

375

450

18

333

400

20

300

360

24

250

300

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Design of E/M Equipment


Comparative table of synchronous and induction generators

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Structure

Synchronous
generators

Induction
generators

Operation

Parallel-in
operation

Excitation
circuit
Relatively large
air gap

Voltage
regulation
Reactive power
adjustment
(Usually lagging
power factor)

Synchronizer
Less electromechanical
impact at parallelin

No excitation
High
maintainability
High rotational
speed

No voltage
regulation
Leading power
factor operation
Only on-grid
operation

No synchronizer
Inrush current
(Parallel-in around
synchronous
speed is
preferable.)

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Design of E/M Equipment


4. Driving Facility (Speed Increaser)
To match the speed of the turbine and generator

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Gearbox type:
The turbine shaft and generator shaft are coupled with 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%, depending on 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%, depending on 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 gearbox
type transmitter is very expensive.

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Design of E/M Equipment


5. Control Facility of Turbine and Generator

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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/Electrical type:
Controls the turbine speed constantly by regulating the guide vanes /
needle vanes according to load. There are two types of power
source:
Pressure-oil type
Motor type
Ancillary Equipment:
Servomotor, pressure pump and tank, sump tank,
piping or electric motor for gate operating mechanism

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Design of E/M Equipment


(2) Dummy load type:
Generator output is always
constant at a micro hydro
power station where a
dummy load governor is
applied to. In order to keep
the frequency constant, the
relationship generator
output = customers load +
dummy load is essential.
The dummy load is controlled
by an electronic load
controller (ELC) to meet the
above equation.

Customers of Electricity

Transformer

Upper Dam

Spillway

Upper Reservoir
Power House
Dummy Load Governor

G-T

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Design of E/M Equipment

The capacity of 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
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Design of E/M Equipment


5.2 Generator Exciter
In the case of a synchronous generator, an exciter is
necessary for supplying field current to the generator
and keeps the terminal voltage constant even though
the load fluctuates. The type of exciter is classified as
follows:
DC exciter:
A DC generator directory coupled with main shaft
supplies field current of the synchronous
generator. The generator terminal voltage is
regulated by adjusting the output voltage of DC
exciter. Maintenance on brushes, commutator is
necessary.

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Design of E/M Equipment


AC exciter:
The excitation 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)

PT
Pulse
Generator

AVR

CT

(Speed Detector)

Ex. Tr

Rotating section
DC100V
G

AC
Ex

Brushless exciter

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Design of E/M Equipment


Static excitation:
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)

PT
Pulse
Generator

AVR

CT

(Speed Detector)

Ex. Tr

Slip ring

Static excitation

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Design of E/M Equipment


6. Switchgears
Single Line Diagram:
The typical single diagram for a 380/220V distribution line

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Magnet
Contactor

A x3
V
V

Hz

Turbine

G
Transmitter
if required

Generator

ELC

(with Hz Relay)

x3
Lamp
Indicator

NFB

Fuse

To Custmer

x3

Dummy Load

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Design of E/M Equipment


Switchgear board including ELC

CB(MCCB)

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ELC

NFB

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Design of E/M Equipment


7. Control Panels

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7.1 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,
one-man control and fully automatic control.
The output control method is classified into dummy load governor
control for isolated grid, discharge control, water level control and
programmable control.

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Design of E/M Equipment


7.2 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 are
required to summarize and check total energy generation at the
power plant

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Design of E/M Equipment


7.3 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 an item 1, 2 or 3 is detected, the protective relay is activated and forces
the main circuit breaker trip. At that time, the unit shall be stopped to check
conditions.

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1-Nov-05 (12:01)
e7 / PPA Workshop on Renewable Energies

Design of E/M Equipment


Exercise
There is a potential site with the following conditions:
Net head: 10 m
Discharge: 1 m3/s
Frequency: 50 Hz
Synchronous generator is required.
Q1: Which types of turbine are preferable for the site?
Q2: How wide of the applicable range of specific speed on
a selected turbine?
Q3: How wide of the rotational speed range will be applicable for
the selected turbine when the turbine efficiency is 0.6?

e7 / PPA Workshop on Renewable Energies

1-Nov-05 (12:01)

53

Design of E/M Equipment


Answer
There is a potential site with the following conditions:
Net head: 10 (m)
Discharge: 1 (m3/s)
Frequency: 50 (Hz)
Synchronous generator is required.
Q1: Which types of turbine are preferable for the site?
A1: Cross Flow, Horizontal Propeller, and Horizontal
Francis
(Please refer to the selection chart.)
Q2: How wide of the applicable range of specific speed on
a selected turbine?
A2: If the horizontal propeller is selected, the range of Ns is
200 900 (m-kW).
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1-Nov-05 (12:01)

Design of E/M Equipment


Selection of turbine type
1000

(3,280)

(m, ft)

Effective Head

e7 / PPA Workshop on Renewable Energies

Horizontal Pelton

Vertical Francis

100

(328)

10

(32.8)

Cross Flow
Horizontal Francis

(3.28)

1
0.01
(0.3529)

0.1
(3.529)

Horizontal Propeller

1
10
(35.29)
(352.9)
3
3
Water Discharge (m /s, ft /s)

100
(3,529)

e7 / PPA Workshop on Renewable Energies

1-Nov-05 (12:01)

55

Design of E/M Equipment


Answer
Q3: How wide of the rotational speed range will be applicable for
the selected turbine when the turbine efficiency is 0.6?
A3: The turbine output P is
P = 9.8 t Q H = 9.8 0.6 1 10 = 58.8 (kW)
so that the minimum and maximum rotational speeds are
calculated as follows:
Nmin
= Nsmin H5/4 / P1/2
= 200 105/4 / 58.81/2
= 463 (min-1)
= 900 105/4 / 58.81/2
Nmax
= 2087 (min-1)
Considering the standard rated speed, the speed range from
500 to 1500 (min-1) is applicable for the direct coupled
generator.
In case that 500 (min-1) is selected as the turbine rated speed
considering turbine characteristics, a speed increaser is
preferable to apply because lower speed generators are costly.
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