Hydro Design & Construction

Hydro, Driven by Solar Power

Hydro power in the World

US Supply

US Renewables

Most of that global hydro power is produced by largescale hydroelectric plants

micro
Small in scale

hydro

Minimum environmental impact Site specific: you must have the resource Affordable. Consistent: Produces continuously, 24/7

Types of Systems
Turbines can be of many forms.
Listed are a few of the major types.
High head Impulse turbines Pelton Turgo Medium head cross-flow multi-jet Pelton Turgo Low head cross-flow

Reaction turbines

Francis Pump-as-turbine (PAT)

propeller Kaplan

Pelton and Turgo Impulse jet of water

Banki and Crossflow Impulse sheet of water

Crossflow

Banki

Francis
Reaction Turbines
Submerged in the flow; driven by the pressure differential

Kaplan

http://www.waterwheelfactory.com/francis.htm http://www.toshiba.co.jp/f-ene/hydro/english/products/equipment/index01_2.htm

Turbines are turned by water. That turning motion drives a generator which produced electricity.

You need two things to make power

Head and Flow

Power Estimates

Gross Power Calculations

Power output is proportional to the combination of head and flow

Power (watts) = Head (ft) * Flow (GPM) 10

The equation assumes a turbine efficiency of 53%. Actual efficiency varies with conditions.

Example

Stream flow = 300 GPM (1/2 of flow is 150 GPM) Total Head is 140 feet
Gross Power Estimate = (140 ft * 150 GPM)/10= 2100 W

Why is this gross power?

These are not accurate calculations because we used the gross or static head instead of the net or dynamic head.
A more accurate power calculation is made after calculating pipe friction losses. Stay tuned................

...or Charts from Manufacturer

P.M. Alternator output in watts

FEET OF NET HEAD

GAL/M 3 6 10 15 20 30 50 100 200 25 25 40 65 130 230 50 40 75 100 150 265 500 580 75 30 75 110 160 250 420 750 900 100 45 95 150 240 350 600 1100 1300 200 45 130 210 320 480 650 1100 1500 300 80 180 300 450 600 940 1500 -

Measuring Head

Measuring Head

5 stick with carpenters level Sight level Water level Pipe with pressure gauge GPS Unit Transit Topo map Altimeter

Measuring Head

5 stick with level (3 people)

Measuring Head

Sight level (2 people)

Eye level

Measuring Head
Water level and measuring tape (2 people)

Water level

Measuring Head
Transit Most accurate if you have the equipment

Measuring Head

Pipe with pressure gauge at the bottom Could use garden hose(s)

2.31

feet = 1 psi

This gauge reads 38 psi 38 psi x 2.31 feet/psi = 88 ft of static head

Measuring Head
GPS, altimeter, topo map Difference in elevation readings

Measuring Flow

Measuring Flow

Units
GPM: gallons per minute CFM: cubic feet per minute CFS: cubic feet per second

How much to use?

Dont take the whole creek! Use minimum flow Avoid taking more than of the Water temp could be effected!!! Let the ecosystem thrive

flow

Methods of Flow Assessment

5-gallon bucket
Small

stream, small waterfall

Float method
Larger,

flat, uniform stream

V-notch Weir Rectangular Weir Make several measurements to assess seasonal variation

5 gallon bucket

5 gallon bucket

If the measured flow using a 5 gallon bucket and a stop watch was 5 gallons in 1.5 seconds, how many GPM would this be?

5 gal 60 sec 200GPM 1.5 sec 1 min

Float method
Big, flat, uniform creek

Float method
Flow (ft3/s) = Velocity (ft/s) x Cross Sectional Area (ft2)

Float method
1.

Calculate the average depth

Lay a board across the stream, measure the depth every foot, average the depths

Float method
2.

Calculate the cross sectional area

Area (ft2) = Average depth (ft) x Width (ft)

Float method
3.

Calculate velocity

Measure where you measured the area, an orange makes a good float, start well upstream, a 10 span is good, average multiple measurements

Float method
4.

Correct for Friction

Flow (ft3/s) = Velocity (ft/s) x Cross Sectional Area (ft3) x .83

Multiply x 0.83 to correct for friction on the bottom of the stream

Float Method
So, if these guys measure this 3 wide stream and get an average depth of 8 and it takes an orange an average 5 seconds to go 10 feet, what is the flow in GPM?

Area = 3 x 8 x (1/12) = 2 ft2 Velocity = 10 ft/5 s = 2 ft/s

Flow = 2 ft2 x 2 ft/ s = 4 ft3/s

4 ft3/s x 7.48 gal/1 ft3 x 60s/1 min = 1795 gpm Correct for friction, 1795 gpm x .83 = 1490 gpm

Weir Method

For larger flows or more accurate measurements Small

V-notch
Rectangular

Larger

All you needs is depth and the table

V-notch Weir

Rectangular Weir

Penstock
the pipe

The Intake
Diverting clean water into the penstock
Screen

Steam Flow

The intakes job:

Filter and Settle

Start of Penstock Build it either:

Simple and easy to repair

Or

Bullet-proof

Steam Flow

The Intake
Diverting clean water into the penstock
Overflow

A dirty creek may need more settling time

Screen

Start of Penstock

Penstock
A full pipe; delivering clean water to the turbine

Pipe can be a Considerable Cost up to 40%

Factors to Consider: Penstock

surface roughness design pressure method of jointing weight and ease of installation accessibility of the site terrain design life and maintenance weather conditions availability relative cost likelihood of structural damage

Burying Pipe

Burying a pipe line removes the biggest eyesore of a hydro scheme. It is vital to ensure a buried penstock is properly and meticulously installed
subsequent

problems such as leaks are much harder to detect and rectify.

Penstock Support System

PVC likes to stay straight HDPE can follow the contour of the ground

Pipe Friction Losses

Must use charts to calculate head loss due to pipe friction Flow varies with D3

pipe can flow 8x more water than 2 pipe

Lets do an example
140 ft static head Pipe = 3 HDPE (High Density Poly Ethylene) What is friction loss for 1300 pipe for a flow of 100 GPM? What is the dynamic or net head?

Lets do an example:
PIPE FRICTION LOSS Polyethylene SDR - Pressure Rated Pipe

Pressure Loss from Friction in Feet of Head per 100 Feet of Pipe

Flow US GP M 0.5 1 2 3 4 5 1.13 4.05 8.6 14.6 22.1 0.75 0.28 1.04 2.19 3.73 5.61 1 0.09 0.32 0.67 1.15 1.75 1.25 0.02 0.09 0.19 0.3 0.46 0.04 0.09 0.14 0.21 0.02 0.05 0.07 1.5 2 2.5 3

90 95 100 150 200 300

13.5 15 16.5 34.5

5.71 6.31 6.92 14.7 25

1.98 2.19 2.42 5.11 8.7 18.4

Lets do an example

Turtle Island 140 ft head 3 HDPE (High Density Poly Ethylene) What is friction loss for 1300 pipe for a flow of 100 GPM? What is the dynamic head?

Chart says well lose 2.42 of head per 100 of pipe. We have 13 x 100 of pipe, so 13 x 2.42 = 31.5 of total head loss Dynamic or net head = 140 31.5 = 108.5

Nozzles

Nozzles
The flowrate from the penstock is controlled by properly sizing the nozzle(s) at the turbine.

Nozzles

What size nozzles and how many would you recommend if one wants to use about of a stream with 300 GPM of measured flow with 100 ft of head (pelton wheel)?

Nozzles
Maximum efficient flow at various heads

From Harris Hydro

(FIGURES IN GALLONS/MIN)

FEET OF NET HEAD

# of nozzles 1 2 3 25 17 35 52 70 50 25 50 75 100 75 30 60 90 120

100
35 70 105

200 50 100 150 200

300 60 120 -

140

300 gpm/2 = 150 gpm usable flow 150 gpm/4 = 37.5 gpm per nozzle

Nozzles
NOZZLE FLOW CHART from ES & D 5/16 3/8 6.18

(4) 7/16 nozzles should do it

FLOW RATE IN U.S. GALLONS PER MINUTE

Head Feet

PSI

Nozzle Diameter, inches 1/8 3/16 1/4

RPM

7/16
8.4 11.6 14.6 16.8 20.6 23.8 26.6 29.1 33.6 8.75 10.7 12.4 15.1 17.5 19.5 21.4 24.7 27.6 30.3 33.8 39.1 43.6 47.8 55.2

1/2 11 15.6 19 22 26.9 31.1 34.7 38 43.9 49.1 53.8 60.1 69.4 77.6 85.1 98.2

5/8 17.1 24.2 29.7 34.3 42 48.5 54.3 59.4 68.6 76.7 84.1 93.9 109 121 133 154

3/4 24.7 35 42.8 49.4 60.5 69.9 78.1 85.6 98.8 111 121 135 156 175 191 221

7/8 33.6 47.6 58.2 67.3 82.4 95.1 106 117 135 150 165 184 213 238 261 301

1 43.9 62.1 76 87.8 107 124 139 152 176 196 215 241 278 311 340 393 460 650 800 925 1140 1310 1470 1600 1850 2070 2270 2540 2930 3270 3591 4140

5 10 15 20 30 40 50 60 80

2.2 4.3 6.5 8.7 13 17.3 21.7 26 34.6 43.3 52 65 86.6 108 130 173 1.37 1.68 1.94 2.17 2.38 2.75 3.07 3.36 3.76 4.34 4.86 5.32 6.14 2.68 3.09 3.78 4.37 4.88 5.35 6.18 6.91 7.56 8.95 9.77 10.9 12 13.8 3.88 4.76 5.49 6.72 7.76 8.68 9.51 11 12.3 13.4 15 17.4 19.9 21.3 24.5 6.05 7.4 8.56 10.5 12.1 13.6 14.8 17.1 19.2 21 23.5 27.1 30.3 33.2 38.3

100
120 150 200 250 300 400

37.6
41.2 46 53.2 59.4 65.1 75.2

Micro Turbines

Efficient, durable, battery charging pelton turbine with an adjustable permanent magnet generator. 20-600 feet of head 2-250 GPM of flow

1 nozzle $1800 2 nozzle $1950 4 nozzle $2150

Energy Systems & Design

Stream Engine
Brushless, permanent magnet alternator which is adjustable Capable of outputs over 1 kilowatt Heads from 6 to 300 feet. Equipped with a rugged bronze turgo wheel, universal nozzles (adaptable to sizing from 1/8 to1 inch), and a digital multimeter which is used to measure output current.

2 Nozzle Bronze 4 Nozzle Bronze High Voltage Option High Current Option

$2395 $2545 $200 $100

www.microhydropower.com

Energy Systems & Design

Low Head Propeller Turbine

Water Baby Uses the same generator as the Stream Engine, however the water Operates much the same as the turbine component uses a low Stream Engine but requires very head propeller design. little water (pelton wheel) heads of 2 feet up to 10 feet. Will operate on as little as 3 gpm but requires at least 100 feet of At the maximum head, the output head. is 1 kW. At a head of 100 feet and a flow of 3 gpm the output is 25 watts; at 24 gpm the output is 250 watts.
$1995 Baby Generator, 1 Nozzle (12/24 volt) $1395

LH1000 with Draft Tube

High Voltage Option

High Current Option

$200 extra
$100 extra

Extra Nozzles (installed)

High Voltage (48/120 volt)

$120 ea
$100

www.microhydropower.com

Hydro Induction Power

Good for long wire runs, 60' 500' head, 10 - 600 gpm
The units produce 3-Phase 120V, 240V, or 480V 'wild' (unregulated) AC, which is then stepped down to battery voltage. The heavy-duty brushless alternator is housed on the Harris Housing Uses the Harris bronze Pelton Wheel for flows up to 200 gpm and the bronze Turgo Runner for flows of 200 to 600 gpm.

HV 600 with 2 Nozzles $2500 HV 600 with 4 Nozzles $2600 HV 1200 with 4 Nozzles $3000 HV 1800 with 4 Nozzles $3500 HV 3600 with 4 Nozzles $5000 Turgo option $600

www.hipowerhydro.com

Hydro Induction Power

Now offer a new LOW VOLTAGE (12V/24V), brushless unit (48V coming in 2006). It can generate either 12V or 24V with pressures from 20psi to 150psi (46' - 400'). Above this pressure, it will generate 48V. Lots of accessories

12/24V Hydro with 12/24V Hydro with 12/24V Hydro with 12/24V Hydro with

1 Nozzle: $1350 2 Nozzles:$1400 3 Nozzles:$1450 4 Nozzles:$1500

Upgrade from Harris Hydro: $500 Turgo option $600

www.homehydro.com

Alternative Power & Machine

Economy models Permanent magnet units Accessories Exercise Bicycle Type Battery Chargers, etc. Niche: Ease of maintenance and adjustment