Multi turbine micro hydro power generation

International Journal For Research & Development in Technology
Volume: 2, Issue: 3, Sep -2014 ISSN (Online):- 2349-3585
10 Copyright 2014- IJRDT www.ijrdt.org
Multi Turbine Micro Hydro Power Generation
Kevin Jacob1
, Kishore K Abraham2
, Mathew James3
,
Naveen Krishnan4
, Manoj Balakrishnan5
12345
Department of Mechanical Engineering,
Saintgits College of Engineering P .O, Kottayam, Kerala.
Abstract— Increase in human population has increased the
demand for energy. Fossil fuels are the major source to meet
the world energy requirements, but its rapidly dwindling
supply and its adverse effects on our ecological system are of
major concern. In India over 70 % of the electricity
generated is from coal based power plants. Other renewable
such as wind, geothermal, solar, and hydroelectricity
represent a 2% share of the Indian fuel mix. Fossil fuels
(coal) are a major source of power production in India. Our
concept features the run of river active setup of micro hydro
power generation using simple gear mechanism. This
concept is based on the collection of mechanical energy from
two rotors spinning by the effect of higher river velocity and
transmission of power from the rotors to a small pinion gear
which runs the generator shaft, through two large driver
gears attached to the shafts of two rotors. This method of
power production is comparatively simpler than others. The
objectives of our project include low cost, higher output,
environment friendly power production, multiple setups in
one row, and decrease the power shortage in India.
Key words: Turbine,Hydro power plant
I. INTRODUCTION
Hydro-power production can be carried out using Turbines and
water wheels. Turbines need extensive potential energy which
means an appreciable head is needed to produce power while
using turbines. On the other hand waterwheels don’t need any
head requirement and it’s the kinetic energy of flowing water
which is used by waterwheels to produce power. Low head and
flow requirements ease in fabrication and relatively low cost
excels them from turbines. These are especially advantageous
to small residential projects where the long payback period of
turbines is prohibitive and hence hydropower production using
waterwheel has become an important source of renewable
energy these days.
A water wheel is a machine for converting the energy of free-
flowing or falling water into useful forms of power. A water
wheel consists of a large wooden or metal wheel, with a
number of blades or buckets arranged on the outer rim forming
the driving surface.
Most commonly, the wheel is mounted vertically on a
horizontal axle, but the tub or Norse wheel is mounted
horizontally on a vertical shaft. Vertical wheels can transmit
power either through the axle or via a ring gear and typically
drive belts or gears; horizontal wheels usually drive their load
directly.
There are different types of water wheel which are being used
throughout the world.
They include:
 Horizontal wheel
 Undershot wheel
 Breast shot wheel
 Overshot wheel
 Back shot wheel

Hydropower installations with a power output less than 100
kW. Large scale hydropower stations are equipped with large
dams and huge water storage reservoirs. In these reservoirs
large amounts of water can be stored when supply of water is
higher than the demand. Water from wet periods can be used in
this way to supplement water supply in dry periods (or even
dry years).
The main objectives of this project work are:
 To introduce a prototype featuring simple mechanism.
 To design the prototype with sufficient cost effectiveness.
 To reduce the chances of pollution, thereby being eco-
friendly.
 Decrease the power shortage in India up to a certain
extent.
HISTORICAL BACKGROUND
Increase in human population has increased the demand for
energy. Fossil fuels are the major source to meet the world
energy requirements but its rapidly dwindling supply and its
adverse effects on our ecological system are of major concern.
In India over 70 % of the electricity generated is from coal
based power plants. Other renewables such as wind,
geothermal, solar represent a 2 percent share of the Indian fuel
mix. Nuclear energy based electricity has a 3 percent share.
Fossil fuels (coal) are a major source of power production in
India. The population of India is currently about 1.2 billion and
there is an annual population growth of 1.3%. It is then
desirable to extract energy from the renewable resources such
as solar, wind and waves. Extraction of energy from wave and
wind energy is not feasible for a developing economy like
India. Also the existing wave energy converters need minimum
of 35-40 kW wave power for power conversion. In the Indian
Ocean the average wave power is about 15 kW. So these wave
energy converters cannot be used for power production.
Production of electricity from nuclear power plant may result
in health hazards including high radiation intensity, risk to
human life and ecology, high initial investment in the power
plant, etc. We propose a run-of-the-river micro-hydro active

Paper Title:- Multi Turbine Micro Hydro Power Generation (Vol.2, Issue-3) ISSN(O):- 2349-3585
system as a viable and localized alternative to classical non-
conventional energy generation systems.
In this concept we will collect the mechanical energy of rotors
spinning by the effect of high velocity river. The energy gained
from multiple set-ups of run of river rotors can be collected
with the help of a gear train. By using a generator attached to
the driven gear this energy can be converted to electricity. This
method of power production is comparatively economical and
simpler than others.
Electric power has become an important and an indispensable
part of daily human activity and is used by several categories of
consumers. Innumerable gadgets depend on electricity in some
form. Industrial application of electric power has no bounds.
Different kinds of machinery, which run on power, are in use
in large, medium and small-scale industries, which have been
major consumers of power.
Table 1 show that the fuel for power production is divided into
thermal, nuclear and hydroelectric. A large portion of power
generation depends on thermal source i.e. burning fossil fuels.
This will lead to adverse environmental impact. One of the
most important and achievable method to produce electricity is
to produce it from renewable resources. But it should have
higher efficiency as well as economically feasible. Power
generation in Germany is mostly depending on solar power.
Photovoltaic (PV) plants produced 27.9TWh in 2012
(19.3TWh in Germany 2011). The production increased by
44% compared to 2011. Solar energy produced 5.0% of the
gross electricity generation in year 2012 in Germany.
Table 1: Total power production of power sectors in
India
FUEL
POWER
(MW)
CONTRIBUTION
(%)
Total 124730.9 65.44
Coal 105437.3 55.32
Gas 18093.85 9.49
Oil 1199.75 0.63
Hydro 38848.40 20.38
Nuclear 4780.00 2.51
Our concept features the run of river active setup of micro
hydro power generation using principles of hydraulics. This
concept explores the possibility of transmitting the mechanical
power gained from run-of-river hydro setup by converting it
into electrical energy. We intend to implement our project in
Kerala which is bountiful in rivers i.e. there 44 rivers in Kerala.
The rivers of Kerala are small, whether considered in terms of
length, breadth or annual stream flow. The rivers flow fast,
because of the hilly nature of the terrain and as the distance
between the mountains and the sea is rather shorter. But the
width of these rivers is very large (in kms)
Micro hydro systems are very flexible and can be deployed in a
number of different environments. They are dependent on how
much water flow the source (creek, river, and stream) has and
the velocity of the flow of water. Energy can be stored in
battery banks at sites that are far from a facility or used in
addition to a system that is directly connected so that in times
of high demand there is additional reserve energy available.
These systems can be designed to minimize potential damage
regularly caused by large dams or other mass hydroelectric
generation sites.
In relation to rural development, the simplicity and low relative
cost of micro hydro systems open up new opportunities for
some isolated communities in need of electricity. With only a
small stream needed, remote areas can access lighting and
communications for homes, medical clinics, schools, and other
facilities. Micro hydro can even run a certain level of
machinery supporting small businesses. Regions along the
Andes Mountains and in Sri Lanka and China already have
similar, active programs. One seemingly unexpected use of
such systems in some areas is to keep young community
members from moving into more urban regions in order to spur
economic growth. Also, as the possibility of financial
incentives for less carbon intensive processes grows, the future
of micro hydro systems may become more appealing.
Micro hydro power is generated through a process that utilizes
the natural flow of water. This power is most commonly
converted into electricity. With no direct emissions resulting
from this conversion process, there is little to no harmful
effects on the environment, if planned well, thus supplying
power from a renewable source and in a sustainable manner.
Micro hydro is considered a run of river system meaning that
water diverted from the stream or river is redirected back into
the same watercourse. Adding to the potential economic
benefits of micro hydro is efficiency, reliability, and cost
effectiveness.
Water current turbines can be installed in any flow with a
velocity greater than 0.5m/s. Because of low investment and
maintenance costs, this technology is cost-effective compared
to other technologies. The continuous supply of electrical
energy is also an advantage in comparison with solar power or
other small scale renewable technologies. This kind of small-
scale hydropower is considered environmental friendly,
meaning that the water passing through the generator is
directed back into the stream with relatively small impact on
the surrounding ecology. Small-scale water current turbines
can be a solution for power supply in remote areas. Because of
the low-cost and durability of this kind of hydro power,
developing countries can manufacture and implement the
technology to supply the needed electricity to small
communities and villages.
We have rivers in Kerala that sustain sufficient flow rate that
enables micro hydro power production as described in the
beginning. These systems can be designed to minimize
potential damage regularly caused by large dams or other mass
hydroelectric generation sites.
DESIGN APPROACH
For any engineering project, proper design and calculations are
very important parameters. Proper design methodology helps in
fabricating a project which is economical both cost wise and in
terms of other parameters like weight, project time etc. There
are various methods for a proper design process. This project
uses a combination of Reverse Engineering, Bottom up Process
etc.
Material selection was one of the most difficult part of the
design process. There is a huge list of variety of different
materials available for selection. Hence some major criteria’s
were shortlisted for the selection of materials. This includes:

 Cost: From the very beginning, the taste of lack of finance
was felt with both in terms of material cost and other
expenditure and for the research and analysis. The lack of
finance demanded that the cost is put down to the lowest
possible value so that the project is successfully completed
with-in the stipulated time period.
 Ease of Availability: Most of the Industries get their
materials from the wholesalers in bulky amounts, which
put a lack of availability of materials in the market of
common people. As students requiring very less amount of
materials for the work, it was difficult to find the materials
in the market.
 Ease of working on it: The lack of advanced facilities in
college forced the project to select materials which can be
worked upon in the machine shop easily enough, with the
requirement of precision instruments. Materials like
stainless steel, structural steel and high strength micro
alloy need advanced machines for working on it.
 Usability: As our project is micro hydro power plant the
material chosen should be able to withstand impact forces
impinging on the blades, sudden shock, weight of each
parts of the prototype etc. A metal to face such conditions
puts the budget list vulnerable. There are just two choices
left out viz, either to choose the most simplest material like
the mild steel, or go to the most extreme, into the search of
alloys.
 During the survey, it was concluded that the most
commonly used material in micro hydro power plant are
stainless steel, structural steel and high strength micro
alloy. But during the survey conducted, it was positively
concluded that stainless steel, high strength micro alloys
are too costly to be bought for a B.Tech final year project;
without the aid of external funds. So we choose 18 gauge
mild steel sheets for making blades of horizontal wheel.
The horizontal wheel for the prototype contains a base plate
and 8 blades with length 50cm and width10cm. As the distance
from the ground to the top surface of the stream was found to
be 30 cm, we chose the blade length as 50cm so that 20cm
remains immersed in water. We also found that if more than
20cm remains immersed in water then the rpm was found to
decrease due to back pressure. Normally for extraction of
energy from flowing water we choose horizontal water wheel’s
blades of curved structure. Since the flow is less it is not
necessary to make the blades in curved fashion.
MODELLING OF GEAR
Perhaps the most often used gears are external spur gears. They
are used to transmit rotary motion between parallel shafts and
the shafts rotate in opposite directions. They tend to be noisy at
high speed as the two gear surfaces come into contact at once.
Prototype contains three gears – two gears and one pinion gear.
The gears are made of cast steel. Gears have 104 teeth and
pinion gear has 24 teeth. Gear is made up of cast iron and
pinion gear is made up of cast steel. The diameters of gear and
pinion gear are 207mm and 48mm respectively. Face width of
both gears is 20mm. The force and torque transmitted from
gear to pinion gear is calculated and shown in analysis chapter.
The gear ratio chosen for our prototype is 4.33.
Fig. 1 Gear mechanism used in the prototype
MODELLING OF SHAFT
The horizontal wheels are keyed to two shafts. The shaft has a
diameter of 15 mm. The shaft carries ball bearings to reduce
the effect of friction arising due to the rotation of the shaft.
Two gears are attached to these shafts. So we have selected the
diameter of shaft through the calculation with the help of forces
given to the shafts by gears (force and torque analysis). The
material of shaft used in the prototype is mild steel.
Fig. 3.3 Design of the shaft fabricated for the prototype
Design of shaft:
The distance between the centre of gear and centre of
bearing, L = 140 mm
Normal load, Fn = N91.274
20cos
33.258
cos
Ft


The value of Ft is obtained from force analysis.
Weight of gear
mbT00118.0W geargear 
gearW = 0.00118×104×20×4
gearW = 9.8176 N
Resultant load,
2
1
gearngearnr ))cosWF2(NF(F 
2
1
r ))20cos8176.991.2742(81762.9912.274(F 
N157.284Fr 
Bending moment on shaft due to resultant load
M = Fr× L
M = 284.157×140 = 39782.09Nmm

Twisting moment =
2
d
F
gear
t 
T= mm26737.465N
2
20733.258


Equivalent Torque, Te
2
1
2222
)465.2673709.39783()TM( 
Te=
16
d3

Shear stress for the cast iron material, τ = 60 N/mm2
d 233 e
mm/N9.14
60
314.4793216T16







Hence diameter of shaft, d = 15 N/mm2
MODELLING OF BEARINGS
Ball and roller bearings are used widely in instruments and
machines in order to minimize friction and power loss. While
the concept of the ball bearing dates back at least to Leonardo
da Vinci, their design and manufacture has become remarkably
sophisticated. This technology was brought to its p resent
state of perfection only after a long period of research and
development. The benefits of such specialized research can be
obtained when it is possible to use a standardized bearing of
the proper size and type. However, such bearings cannot be
used indiscriminately without a careful study of the loads and
operating conditions. In addition, the bearing must be provided
with adequate mounting, lubrication and sealing.
A ball bearing usually consists of four parts: an inner ring, an
outer ring, the balls and the cage or separator. To increase the
contact area and permit larger loads to be carried, the balls run
in curvilinear grooves in the rings. The radius of the groove is
slightly larger than the radius of the ball, and a very slight
amount of radial play must be provided. The bearing is thus
permitted to adjust itself to small amounts of angular
misalignment between the assembled shaft and mounting. The
separator keeps the balls evenly spaced and prevents them from
touching each other on the sides where their relative velocities
are the greatest. Ball bearings are made in a wide variety of
types and sizes.
Fig.
3.4 6020 ball bearing
The heavy series of bearings is designated by 400. Most,
but not all, manufacturers use a numbering system so devised
that if the last two digits are multiplied by 5, the result will be
the bore in millimeters. The digit in the third place from the
right indicates the series number. Thus, bearing 307 signifies a
medium-series bearing of 35-mm bore.
The ball bearing we have chosen for prototype is 6020 steel
ball bearing. 6020 steel ball bearing is a standard ball bearing
available in market having inner diameter 15mm. Inner
diameter 15mm is chosen because the shaft which is designed
for our prototype having diameter 15mm.
TESTING AND EVALUATION
The horizontal wheel works with a high flow of water and
consists of a rotor, a shaft, and a generator that will produce a
DC current. The shafts attached to both the horizontal wheels
transmits power arising from the horizontal wheel to the gears
attached on it. The gears rotate with the rotation of the shafts.
A pinion gear is attached between both the gears. The
rotations of the gears also rotate the pinion gear. The pinion
gear is coupled to a generator. The rotation of the pinion
actuates the generator and a definite amount of electrical
energy is produced. Thus the kinetic energy of the high
velocity river is converted to electrical energy.
Table 4.1 Observation
Sl.
No:
Discharge
(m3
/s)
Speed of
the gear
(rpm)
Speed of the
pinion (rpm)
1 .862 X 10-4
33 143
2 .91 X 10-4
35 152
3 .94 X 10-4
36 156
4 1.01 X 10-4
39 169
5 1.02 X 10-4
41 178
POWER TRANSMITTED TO PINION GEAR
The discharge of the runoff river was measured using the
float method. Then force, torque and power transmitted to the
pinion was calculated and tabulated in the table below.
Table 4.2 Power transmitted to pinion gear
Sl.
No:
Speed
of the
pinion
(rpm)
Force
(N)
Torqu
e
(Nm)
Power
input
(W)
1 143 258.3 6.2 92.845
2 152 254.2 6.1 97.095
3 156 252.9 6.07 99.161
4 169 248.3 5.96 105.69
5 178 245.8 5.9 109.97
Figure 4.1: Speed vs torque
5.7
5.8
5.9
6
6.1
6.2
6.3
143 152 156 169 178
Torque(Nm)
Speed of the pinion(rpm)
Torque
(Nm)

POWER PRODUCED BY THE GENERATOR:
The voltage and current produced by the generator was
measured using a multi-meter. After measuring the voltage and
current, the power produced by the generator was calculated
and tabulated below.
Table 4.3 Power produced by the generator
Sl.
No:
Speed of
the pinion
(rpm)
Voltage
(V)
Current
(A)
Power
output
(W)
1 143 12.2 2.86 35
2 152 12.5 3.04 38
3 156 12.8 3.046 39
4 169 13 3.15 41
5 178 13.5 3.141 42.4
EFFICIENCY:
Table 4.4 Power vs efficiency
Sl.
No:
Power
transmitted to
the pinion
(W)
Power
produced by
the
generator
(W)
Efficiency
(%)
1 92.845 35 37.69
2 97.095 38 39.145
3 99.161 39 39.32
4 105.69 41 38.75
5 109.97 42.4 38.55
Figure 4.2: Speed vs efficiency
CALCULATION
For convenience, the calculation of the first set of readings
in the observation column is taken.
14.975m/s
60
143π2
60
Nπ2
ω
pinion
pinion 




s/m3594.0024.976.14rvpinion 
89.0
03594.05.3
05.3
v05.3
05.3
Cv 




MPa6.220d 
2
24
48
T
d
m
pinion
pinion

Lewis equation:
3
1
pinionvd
st
TyKC
CM2
m











10
m
m10
m
b
K 


116.0
24
912.0
154.0
T
912.0
154.0y
pinion

Put equations (3),(4),(6),(7) in Lewis equation (5):
3
1
pinionvd
st
TyKC
CM2
m











3
1
t
24116.1089.6.220
1M2
2 








Nm2.6Mt 
Tangential force acting on the pinion thus obtained is:
N33.258
48
62002
d
M2
F t
t 




Power transmitted to pinion:
W845.923594.033.258vFP piniontin 
V2.12)V(Voltage 
A86.2)I(Current 
Power produced by the generator
W3586.22.12IVPout 
%69.37
845.92
35
P
P
=Efficiency
in
out

ACKNOWLEDGMENT
We express my heartfelt gratitude to GOD almighty for
being the guiding light throughout our project, without whose
intercession this project would not have been a reality. I
thank our parents for being a guiding light and supporting me
all throughout my life.
We would like to extend my sincere thanks to my Principal
Dr. M. C Philipose, Er. Muruganantham P (head of the
department), and Manoj Balkrishnan (Asst. Professor),
department of Mechanical Engineering for rendering all the
facilities and help for the successful completion of my
project.
Last, but not the least, I am thankful to Dr.Sreejith C. C.
(Project coordinator), Er. Sajan Thomas, Er. Ron P., Er.
Sajeev A., Er. Nikhil Ninan, who guided and supported me
in my hard times and gave me an opportunity to present the
project successfully.
REFERENCES
[1] O Ankur, G Samarjit, K Rajnish, “Indian power systems
and opportunities” International Journal of Advanced

Research in Electrical, Electronics and Instrumentation
Engineering, Vol. 2, Issue 3, March 2013.
[2] D Himachalam, K.S Murthy, “Efficiency of Indian Power
Sector an Analysis of its Performance and Problems”,
IJMBS Vol. 1, Issue 3, September 2011.
[3] A. Varughese, P A Michael, “Electrical Characteristics of
Micro-Hydro Power Plant Proposed in Valara Waterfall”
International Journal of Innovative Technology and
Exploring Engineering, IJITEE, Volume-2, Issue-2,
January 2013.
[4] P. Oliver, “Small hydro power: technology and current
status”, Elsevier publications, Renewable and Sustainable
Energy Reviews, Vol. 6, pg. 537-556, 2002.
[5] Energy statistics 2013, central statistics office, National
statistics organisation, Ministry of statistics and
programme implementation, Government of India.
[6] Machine design data book, Mahadevan.

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