The hydroEngine

TM

Delivering distributed,
utility-scale, renewable energy

TM
The hydroEngine
 01 Introduction Index 02

T he hydroEngine™ combines the simplicity,

low cost, and freedom from cavitation of impulse
The device is well suited to low head hydropower
applications because, due to its unique mechanical
03 Operation 12 Types of site

turbines in a compact, easy-to-install package

comparable in size and power output to more
configuration, it can pass large flows at low heads,
while maintaining high shaft speeds.
04 Operating envelope 13 Grid interconnection

expensive Kaplan-type turbines.

05 Efficiency 14 Plant safety

06 Examples 15 Operations and maintenance

07 A water-to-wire offering 17 Design and quality

09 Typical plant layout 18 Environment

TM
TM

The hydroEngine
The hydroEngine
 03 Operation Operating envelope 04
How the hydroEngine™ works SLH system rated capacity

ft m 50 kW 100 kW 500 kW 1000 kW

65.6 20

T he hydroEngine™ is a unique 2-stage axial-flow

hydraulic machine optimized for low head large
flow hydroelectric generation.
the moving blades, the water flows through a second
cascade of guidevanes, and finally, passes through
a second cascade of moving blades.
2015
PRODUCTS:
32.8 10 SLH100-M
Water, conveyed in a pipe or penstock, enters The guidevanes inside the hydroEngine™ adjust pitch
SLH100-H
the hydroEngine™ and first encounters a cascade automatically, allowing for direct control of flowrate,
of fixed foils, called guidevanes, which direct flow into while keeping the machine’s efficiency high across
the first cascade of moving blades. After passing over a wide range of flows.
19.7 6

net head
16.4 5

13.1 4 10 kW CURRENT
PRODUCT:
SLH100-L
9.8 3

6.6 2

7 11 18 35 71 106 177 353 706 ft3/s

0.1 0.2 0.3 0.5 1 2 3 5 10 20 m3/s

unit flow Figure 2

TM
TM

The hydroEngine
The hydroEngine

FLOW N atel currently offers the SLH100, which produces

up to 1 MW. SLH100-L

nethead flow power

There are three models of the SLH100: the SLH100-L,
rated to a maximum power of 500kW at 20 feet (6 m ft m3/s ft3/s KW HP
meters) of net head with 10.1 m3/s; the SLH100-M, 1.5 5 6.94 245 82 109
rated to a maximum power of 750kW at 39 feet (12
2 6.6 8.01 283 125 168
meters) of net head with 8.3 m3/s; and the SLH100-H,
3 9.8 9.81 347 231 309
rated to a maximum power of 1MW at 59 feet (18
meters) of net head with 6.7 m3/s. 4 13.1 10.8 381 346 465

5 16.4 11.5 407 462 619

To optimize profitability, projects should be designed 6 19.7 11.4 402 526 705
such that installed SLH’s will operate near their
Figure 1 maximum flow capacity, given the available net head. Table 1
 05 Efficiency Examples 06
High performance across wide range of conditions Rated capacity and efficiency at your site

Head measurment
head example
18 Tot stream flow

We have not developed Make a flow

1 is 2.5 m < hg < 21 m ? no 14
an SLH system suitable duration curve

flow [cms]
10
for your site yet.
0.9 6
yes SLH100 flow

2
0.8 Head loss estimate Net head = 4 m SLH10 flow
0% 25% 50% 75% 100%
We have not developed % of time flow exceeded
0.7 is 2 m < hn < 18 m ? no
Efficiency, / *

an SLH system suitable

for your site yet.
0.6 From Fig. 2, find Q*, Q* = 9.6 cms
Qd for the most Qd = 9.6 cms
yes applicable SLH unit max = 74%
0.5

0.4 intake loss 1, SLH100-L unit

* = best efficiency
0.3 2m < hn < 18m % time stream
Qu Q/Q* P E
Q* = flow at best efficiency point SLH 2.5m < hg < 21m exceeded flow m3/s % h/ * kW kWh
0.2 100 0 0 0 0 0 0
outlet loss
90 0 0 0 0 0 0
0.1 80 0 0 0 0 0 0
70 0 0 0 0 0 0
0 60 0 0 0 0 0 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 50 0.9 0.9 10 0 0 0

Flow, Q/Q*
Data quantity
flow 40
30
6.6
9.5
6.6
9.5
70
100
0.8
1
152.3
250.2
133,379
219,158
20 11.5 9.6 100 1 252.6 221,258
Figure 3 Have you collected Please, gather as 10 13.7 9.6 100 1 252.6 221,258
no

TM
TM

a minimum of a full much data as possible. 0 18.8 9.6 100 1 252.6 221,257

The hydroEngine
The hydroEngine

season of data? 5-10 seasons are ideal. Annual energy generated: 1,016,309

yes Q: unit flow = min (stream flow, unit design flow)

T
Data frequency Q/Q* = unit flow/unit flow at best efficiency point
he hydroEngineTM maintains high efficiency At certain heads (see Figure 3), the machine : efficiency = derived from efficiency curve
h/ *
across a wide range of operating flows. is capable of operating at flow rates up to 120% the Do you have daily no Please, gather as P: power = * g * hnet * Qu
or weekly flow much data as possible. E: energy = P * time
peak-efficiency flow rate. At these larger flow rates, data? Daily to weekly data = x x x
h/ * h mech elec
Internal guidevanes, similar to wicket gates, control the engine will produce more power (and generate are ideal.

both the rate of flow while keeping efficiency high.
To determine the efficiency curve of an SLH unit
at a particular site, the above figure can be utilized.
Peak hydraulic efficiency is about 78%.
Using its internal guidevanes, the engine can
modulate flow rates to values both greater than
and less than the peak-efficiency flow rate (Q*).
more revenue), but the efficiency will be slightly lower yes
than its peak value.
The example above shows a site with a maximum
The flow rate can also be reduced to a value as low as
20% of peak-efficiency flow before the efficiency falls
below 60% of its peak value.
D etermining the correct size and number of
hydroEnginesTM for each project starts with
determining the flow and head duration curves for
flow of 600 cfs (17 m3/s cms). The flow duration curve
for the site, represented by the “Total Available Flow”
line, was constructed from several years of historical
the site in question. This data is input into a model flow data, and for this example, the head is constant
which optimizes the power generated versus because the site is in a regulated water canal. This site
investment required. has adequate flow to take 1 SLH100.
 07 A water-to-wire offering 08
Equipment and weight

Control Panel

Gearbox

Generator

Items included

Draft tube Items not included

Penstock SLH
Intake Adaptor Figure 5

Items included in water-to-wire package Items not included Available Engineering services

Hydro‐mechanical equipment Instrumentation and control equipment The following items are not included in the Supplier • Penstock and draft tube optimization analysis

TM
TM

scope: • Flow analysis

The hydroEngine
• SLH hydroEngineTM, including: • Local plant electrical and control panel
The hydroEngine

• Plant layout
• Construction of weir or dam, powerhouse
- Removable lid
• SCADA plant remote‐control system (hardware and any associated civil works
- Removable cassette module SLH100-L
and software) allowing access to the following:
- SLH case • Furnishing and delivering of gates (except wicket COMPONENT KG LB
- hydroEngineTM, including remote startup gate), stop logs, and trash racks
• Intake adapter Intake Adapter ** 1,270 2,800
and shutdown
• Intake adapter flange • Furnishing and delivering of main transformers SLH Cassette 2,800 6,173
- Intake and bypass gates, and water level
• Gearing - Utility interconnect • Furnishing and delivering of overhead traveling SLH Total 4,300 9,480
• Hydraulic power unit and pressure supply system cranes Gearbox 1,050 2,300
• Special assembly tools • Sensors integrated into control system:
• Construction of temporary facilities and Generator 1,640 3,600
- hydroEngineTM tachometer services including electric power, communication Draft Tube TBD*
Electrical equipment - Hydraulic pressure facilities, water supply, sanitary facilities,
* Based on material
- Water level, upstream and downstream construction camp, etc.
• Generator ** Actual mass depends on pipe dia
- Water static pressure
• Switchgear • Penstock and draft tube
- Vibration Table 2
 09 Typical plant layout 10
Configuring the hydroEngine™ system for your site

Run of river or in-dam Top View

SLH100-L

T he hydroEngineTM is delivered to the project site Ø pipe in 84 90

914 mm Access envelope: 3 ft clearance from the machine in each direction.
In case of multiple installations the clearance is reduced. ranges
as a compact unit, fully assembled and factory- [36”] mm 2,133 2,286
tested. Commissioning time and cost are reduced as Note: PTO position can be mirrored in 53 61
about flow centerline and SLH shaft axis. A
installation into the prepared powerhouse can mm 1,349 1,549
be accomplished in a simple operation. Shut-off gate D
16.7°
Table 3
In most gravity-head situations (run-of-river or
in-dam), the following guidelines are recommended:
E F 10° C

• Intake should be placed a minimum of 1 pipe SLH100-L

diameter below the upper pool, to avoid in mm
A B
ingestion of air. A See Table #3

B 617 15,677
• Draft tube outlet must be submerged at all times
C 138 3,494
of expected operation. It is recommended to
D 169 4,300
submerge the upper edge of the draft tube * Minimum Clear Height
outlet a minimum of 12 inches, or 1/4 draft tube E 43 1,100
= 0.25*J if cassette removed to the side.
outlet height, below the lower pool surface. ≥ 1.25*J if cassette removed vertically. F 87 2,200

G 63 1,600
Side View SLH100
The hydroEngine™ allows for reduction in civil H 49 1,240
works cost because it is not at risk for cavitation.
Minimum J 104 2,650

TM
TM

In most cases the hydroEngineTM can be situated Clear Height*

The hydroEngine
K 535 13,600
The hydroEngine

above the lower pool, reducing the need for Draft tube can be shorter
Inlet L 52 1,322
excavation. In addition, the hydroEngineTM H
than shown
Submergence
can be placed in a small vault, with all control Shut-off gate Ø pipe K M ≥ (5 · L · E) / (L + E)
≥ ø Pipe
G
and electrical equipment on a higher floor, J Table 4
further reducing civil works costs (figure 7).
10° Draft tube can be positioned Outlet
at angles other than shown Submergence
≥ 12”

L M

Figure 7 Figure 6
 In Pipeline

Types of site
SLH100-L
11 The SLH can be easily installed in low-pressure pipeline
in mm 12
A See Table #3
settings. For example, it can be integrated as an energy-
recovery device in parallel with pressure-reducing valves. B 169 4,300 Installing the hydroEngine™
For the most efficient performance, the divergence angle C 87 2,200 in constructed or natural waterways
on the engine’s outlet should not exceed 10 degrees. E 63 1,600
F 49 1,240

914 mm
G 104 2,650

T Run of river
[36”]
he hydroEngine™ can be integrated into any kind
Table 5
of low head hydropower setting, including in-
conduit, run-of-river, in-dam, and directly in pipelines. dam, weir, or
drop structure
16.7°
B
Where possible, the run-of-river approach is favored,
C 10° as it provides inherently more protection from debris,
allows straightforward maintenance when necessary,
Access envelope: 3 ft clearance from the machine in each direction.
and has less impact on the main water channel during
In case of multiple installations the clearance is reduced.
A construction. trash rack
Note: PTO position can be mirrored
about flow centerline and SLH shaft axis
E For any application except for in-pipe flows, it is
pipe SLH draft tube
D critical to properly design the plant trashrack to
F
screen debris, while minimizing maintenance and
ø Pipe
head losses. Placing the trashrack at an angle to the In-dam
main stream flow, as illustrated in Figure 10, can allow
Figure 8 most floating debris to passively bypass the plant.
The trashrack can be additionally protected by an dam
upstream float or boom.
Generator options Figure 9

PARALLEL GEARBOX 90-DEG GEARBOX

Irrigation Application

TM
TM

Top view Front view Top view Front view

The hydroEngine
The hydroEngine

Gearbox
Generator
Gearbox SLH Gearbox Generator SLH trash rack SLH draft tube
Drop structures and check-drop structures represent
SLH ideal opportunities for energy recovery. Power plants
Gearbox
Generator built on irrigation drops with Natel hydroEngines™
SLH
Generator
generate clean energy and profits with only small In pipe
modifications to the existing infrastructure.
pressure reducing valve

Natel generally recommends the “run-of-river”

PARALLEL GEARBOX, U-TURN BELT DRIVE SINGLE-STAGE
Generator configuration for irrigation drop-structure energy
Top view Front view Top view Side view
recovery projects. This type of design ensures that
Gearbox Generator SLH SLH
the normal function of the drop will never
Generator
Gearbox be compromised by power plant operation.
SLH

SLH
Generator
pipe SLH draft tube
Figure 10
 13 Grid interconnection Plant safety 14
Grid-connected induction Ensuring safe operations
generator hydroelectric station for man and machine

T he single line diagram for a grid-connected

hydroEngine™ is shown in this figure. In most
circumstances, an induction generator provides
Control Panel

Natel’s UL508 compliant control panel provides

Runaway/Overspeed

If the generator is disconnected from the

autonomous plant startup and shutdown. Vibration hydroEngine™ while generating power, it is possible
the simplest means to generate electricity in a
monitoring and fault detection is available, alerting that the hydroEngine™ shaft speed will increase up
Utility grid-connected configuration, since no
Transformer the plant manager in advance of mechanical issues. to 2-2.4X normal operating speed, depending on the
frequency control is required.
The control panel features a touchscreen HMI guidevane setting when the runaway initiates. Natel’s
interface for reviewing performance data and system control system will instantly detect the initiation of
Natel will select and configure the plant switchgear
Utility status, manually controlling gates, enabling/disabling runaway and shut down the hydroEngine™ gracefully.
and power factor correction equipment to comply with
Plant Owner run mode, and adjusting target operating parameters.
the local utility’s interconnection requirements. Relays
The control panel uses an Allen Bradley PLC, which
and a series of permissives provide safety to both
Utility has a large base of qualified service providers--no
Bi-directional the utility, and to the powerplant.
Meter proprietary or obscure interfaces/software.

A bidirectional meter measures the net energy

The control panel also provides remote site
generated at the site.
monitoring and manual-override control capabilities.
Its HMI interface is compatible with OPC servers and
Generator output*
DS1 can easily tie in with existing SCADA packages.
G Service Entrance
N F1 • Voltage: 480 VAC
Section (SES1)
• Frequency: 60 Hz or 50 Hz depending
on the utility grid Flow Control
• 3 phase The hydroEngine™ has an internal ability to control

TM
TM

TVSS1
flow rate, using its adjustable guidevanes. Under

The hydroEngine
The hydroEngine

* Generators are specified and sourced individually for each site

depending on kW and utility requirements. normal operations, the plant control system will
make small adjustments to the flow rate from time to
CB2 CB1
time, as necessary to meet the preset plant operating
DS Disconnect Switch goals (such as maximizing energy output, or
PFC1
F1 Fuse maintaining water level). If required, the guidevanes Figure 12
CPT1
CT1 C2 G Ground can close to a point almost, but not completely,
PM1 Water Hammer
Induction Generator N Neutral
reducing the flowrate to zero. In addition to the
Controller (IGC1)
CT2 TVSS Transient Voltage Surge Suppression
internal guidevanes, Natel recommends installing a The main scenario which may lead to large pressure
CB Circuit Breaker
separate gate near the plant intake, capable of totally fluctuations in a hydroEngine™ plant is runaway. If
CPT Control Power Transformer
GPR1 dewatering the plant for maintenance purposes. the hydroEngine™ is experiencing a runaway situa-
C Contactor
C1 tion, the flow rate may drop by 30-40%, depending
CT Current Transformer
PFC Power Factor Correction Capacitors upon the guidevane setting prior to runaway. In most
PM Power Meter situations, the penstock length is so short that water
Induction Generator (IG1)
(Driven by HydroEngineTM) GPR Generator Protection Relay Figure 11 hammer is not an issue.
 15 Operations and Maintenance 16
Ensuring high availability

Life cycle
The SLH system is designed for a 20-25 year
project life with regularly scheduled maintenance on
the powertrain every 3 to 5 years, depending on
the capacity factor of the specific project.
Debris management and water quality
Large, rigid debris should be passively bypassed with
good plant design, or screened out of the intake with
a trashrack. Abrasive particulates should be settled
prior to the hydroEngine™ intake.
gates or valves, inspect all surfaces for fouling and
clean or apply countermeasures as necessary, ensure
plant ingress and egress in good condition, ensure
plant maintenance equipment such as hoists are
in good operating condition).
A chainfall or similar type of hoist can be utilized
to remove the cassette for maintenance that
cannot be performed in-situ.
Cavitation

Materials of construction
Submersible components in the hydroEngine™
are composed of galvanically compatible, corrosion
resistant materials with high fatigue strength.
For example, most structural components are
manufactured from 304, 316, or 17-4PH
stainless steels.
Figure 13
The main power transmission belts inside the The hydroEngineTM is not at risk of cavitation when
For sites with high debris loading, and risk of debris applied in its normal range of operation. This
hydroEngine™, along with the wear faces of the main
entrainment within the hydroEngine™, the upstream improves long term maintenance and operation,
shaft seals, are designed for a 15,000 hour life at
cascade of guidevanes will be kept clean by an and provides good environmental performance.
full load. For a plant with a 50% capacity factor and
automatic cleaning rake module, which physically
running at full rated head, this works out to a overhaul
removes any foreign objects which might become
interval of about 3.5 years. Temperature changes
entrained on the leading edges. The moving blades
within the hydroEngine™ are self-cleaning, as the The hydroEngineTM has been designed to
All moving components in the hydroEngine™ are
blades’ leading edges become their trailing edges accommodate a wide range of temperature
contained in an easily-removed cassette module.
once per revolution. fluctuations. Water temperatures can range from
To access the cassette module, the hydroEngine’s™
sideplates and cover plate are removed. freezing up to 80F (27C) with no deleterious
The hydroEngine™ is capable of operating impact on operations.
in brackish water.

Figure 14
Maintenance

Natel recommends a combination of routine

TM
(annual) inspection and periodic overhauls, to keep
TM

The hydroEngine
The hydroEngine

your hydroEngine™ power plant in good running

condition.

Annual inspections should include a review of the

cassette (check belt and sprocket condition, check
guidevane bushings, inspect shaft seals), power
takeoff system (check gearbox lubricant level and
condition, check any belts, check shaft alignment,
check seals), hydraulic power system (replace filters,
check hoses and fittings for leaks or other symptoms
requiring replacement, check fluid and replenish or
replace as necessary), electrical equipment (inspect
wiring and sensors; ensure leads, cables, terminations
are in good condition), and balance of plant (inspect
flanges for leakage; inspect fasteners, flow control
 17 Design and quality Environment 18
Reliable, innovative hydropower products. Designing power systems to enhance
the health of streams and rivers

Fish friendly Watershed friendly

N atel is dedicated to thorough engineering to

produce high-quality energy products. Its team
of experienced, world-class engineers hails from the
top schools in the U.S.A.: MIT, UC Berkeley, UC Davis,
and the University of Illinois at Urbana-Champaign.
Natel’s products are designed with modern 3D
Computer Assisted Design (CAD), using finite element
analysis (FEA) and computational fluid dynamics
(CFD) methods to exhaustively analyze and optimize
performance.
Natel subjects key components to millions of load
cycles on fatigue testing rigs to pre-emptively identify
and eliminate weaknesses.
Natel also has strong ties to other participants in the
hydropower industry, including the US. Department
of Energy, Alden Research Laboratory, and Oak Ridge
National Laboratory.
Due to low fluid relative speeds, low blade
speeds, and high static pressures, the hydroEngineTM
can coexist peacefully with fish and other aquatic
organisms. Specifically, the hydroEngineTM
accomodates downstream fish passage of
anadromous fish smolts. Upstream passage
of spawning adult fish can be accomplished
with conventional fish ladders, at the low head
drop or diversion.
Natel’s low head hydroEngineTM enables an
alternative vision of watershed development, which
allows recovery of large quantities of hydropower, but
without the conventional damage to riparian domain,
agriculture, and other traditional watershed uses.
Through the intelligent development of specific low
head hydropower projects throughout a watershed,
combined in some cases with peaking storage
reservoirs, the majority of the hydropower potential
of a watershed can be recovered, with minimal
impact. We call this vision EcoSmartHydroTM Power.

Contours of absolute pressure Figure 13 Figure 14

1.77 atm

TM
TM

The hydroEngine
The hydroEngine

1 atm

0.42 atm
 Contact us

980
880

Oakland

e
ub
St T

be
y Tu
ter
bs

e
Pos
We
Alameda
Ma
in
Monarch St.

St.

Willie Stargell Ave

Constitution Way
Webster St.
W Tower Ave
Natel
Energy Atlantic Ave
TM

Pacific Ave

We look forward to your inquiry.

Natel Energy, Inc.

2175 Monarch Street
Alameda, CA 94501 USA

Tel. 510.342.5269
www.natelenergy.com
info@natelenergy.com
v8- Oct2014