ACKNOWLEDGEMENT

We are thankful to our teacher Er. Dinesh Ghimire, Department of Electrical Engineering,
Institute of Engineering, Pulchowk Campus for helping in our visit about necessary
requirements and process for micro hydro design. Also we are very grateful to him for
giving us the opportunity to accomplish the task which has helped us to explore the
practical side, apart from the theoretical knowledge only. Thus, it broadens our mind and
we are able to deal with upcoming future design activities.

Our special thanks go to Mr. Anjan for assisting and guiding us during the visit. He has
assisted us in guiding us towards each and every step in computation of the distribution line
parameter. We would also like to thank all the operation committee members, operators and
local villagers who helped us by providing us the necessary information and replied to our
questions related to technical and socio-economic factors of the project.

We would also like to express our deep gratitude to our families and friends in creating an
environment to accomplish this report.

Group Members
Prakash Pandey 070BEL330
Rochak Silwal 070BEL334
Sagar Bhatta 070BEL335
Samar Bariya 070BEL336
Bimal Gyawali 070BEL349
 OBJECTIVES
Following were the objectives of our visit:
 To study and view the present civil, mechanical and electrical works of the visited
micro hydro project
 To measure the head and discharge of the visited project and do required calculation
for micro hydro design based on our study
 To study the socio-economic condition of the beneficiary group from the micro
hydro
 To design a complete micro hydro scheme for the visited site after technical and
socio-economic study
 METHODOLOGY

Before Visit During Visit After Visit

Brief study of the present
Select the Micro Hydro Visit scheme Sort out the measured data and
Site find out the necessary results
( Civil mechanical and electrical
works)
Design the micro hydro scheme
Prepare the necessary
Measure the head and based on the results and social
document to facilitate the visit
Discharge meeting

Collect the required euipments

for site study Social Meeting with the beneficiary
group about present situation and
socio-economic condition of the
consumers
 INTRODUCTION TO THE SITE
General Information
Site Location: Mahadevsthan, Dhading
Name of Project: Malekhu Khola Micro Hydro Project
Service Area: Mahadevsthan
Plant type: Run-off River
River: Malekhu khola

Technical Information
 Civil
11 month exceedance flow : 67 l/s
Design discharge : 212 l/s
Gross head : 25 m
Power output : 26kw
Head race : stone soling with cement pointing (1.2km), pipe canal (114 m)
 Mechanical
Turbine:
Type : Pelton
Gross head =27m
Discharge =22 l/s
Shaft power =26.73 kw
Coupling system: Direct coupling
 Electrical
Generator:
Type=Synchronous
Voltage = 400v, 3 phase
Capacity=40 kva
Speed=1500 rpm
Governing mechanism: ELC with ballast load
Ballast capacity=22kw
3 phase
Special feature with over/under voltage trip circuit, current and frequency protections.
Water sealed ballast heater tank holding ballast heater
Transmission/distribution system: overhead

Aim of project:
 Village electrification for lightning and development of small- scale industries
 PRESENT STATUS OF PROJECT
Socio-Economic Condition
Ethnic groups:

There are 150 households, which are benefited from this MHP scheme. The total population
benefited by this project is about 900. Communities like Tamang, Chhetri and Damai/Kami
are residing in the project area. Tamang holds the majority of almost more than 95% but
other communities also are in same respect.

Economic condition

Economic condition of the village is not very sound. Illiteracy percentage is high. The main
source of income of the people is agriculture. Almost 90% household depends upon
agriculture. In average 4 persons per household are involved in agriculture. About 10%
household depend on labor works; in an average one man per household is involved.

Land holdings and uses

Average land holdings per household in the project area are 14 ropanies. The major crops
grown are rice, maize, wheat, millet, oilseeds etc. besides potatoes, garlic, beans and orange
are major horticultural crops grown in the vicinity.

Canal utilization on irrigation purpose

The main crops grown in the vicinity are rice, maize, wheat and vegetables. Implication of
irrigation has increased the land yield. The water output for irrigation purpose is designed to
be 12 l/s. with this large land has been irrigated under different cropping pattern.

Marketing and agricultural commodities

Farmers growing cereal crops generally get their cereal products milled at an agro-processing
unit (Ghatta). Farmers engaged in vegetable growing sell their products to local main bazaar
Nau khande, Palung, Hetauda, Tistung and products go to Kathmandu also for which
middlemen plays significant role in determine price of the commoditized.

Management and organizational structure

Villagers have already formed the users committee. Their organizational structure for this
project is shown as below:

Users Management Committee Operator selected by

Community (selected from user) management (paid)
Characterization of the Project
Flow, head and power output

Originally, the discharge measured was 150 l/s with salt dilution method. The minimum flow
has been determined and the 11 months exceedance flow is 67 l/s. the design discharge is 22
l/s and extra 12 l/s is designed for irrigation purpose.

The system has been designed with an overall efficiency of 50%, which is fairly in safe side
for the project with Pelton turbine.

Diversion and intake

The intake location is at Ghatte khola ward no. 3 has been fixed after supervision and
consultation with the villagers. As the 50% of the canal length passes through ward 3 the
locals has purposed to use the canal for irrigation in non-lighting hours. The semi-permanent
gabion wall with 1 m high is constructed for the maintenance of design flow with minimal
head loss during the low flow period. The site intake with rectangular orifice of 0.1m* 0.5 m
has been made. A coarse trash rack has also been proposed from flood risk for which, 15m
long and 4 m high gabion is made.

Gravel trap and spillway

The gravel trap and other structures like desanding basin and spillway has been made. The
size of the gravel trap is 2m long and 0.5 m wide and 2.96 m of collection depth, which is
located close to intake. The spillway in the canal just after the gravel trap is with 3m wide.

Canal
Type = trapezoidal stone soling with cement pointing
Top width = 0.7m
Bottom width = 0.3m
Side slope = 1:1
Free board = 0.3m
Depth = 0.2m

Penstock pipe
Penstock pipe connects the forebay tank with the turbine. The penstock length of the project
is 221m.
HDPE pipe of OD 250 mm, 4-kg/cm3 [79 m]
MS pipe of ID 200 mm, 3.0-mm thick (33m)
MS pipe of ID 200 mm, 3.5-mm thick (109m)

Expansion joint
Expansion joints 5 nos. is used after every anchor blocks.

Anchor blocks
There is one horizontal bend and two vertical bends. For the support of MS penstock pipe
portion, 5 anchor blocks are used.
Support piers
36 numbers of support piers are used to support the MS pipe portion. Pipe clamp are used to
restraint the movement of penstock pipe in the later direction and tarpapers are used to reduce
the friction while it moves along its longitudinal axis in the temperature variation.

Turbine:
Type: pelton
Gross head =88m
Discharge =42 l/s
Shaft power =26.73 kw

Generator:
Type=synchronous
Voltage = 400v, 3 phase
Capacity=40 kva
Speed=1500 rpm
Coupling system: direct coupling

Governing mechanism:
ELC with ballast load
Ballast capacity=22kw
3 phase
Special feature with over/under voltage trip circuit, current and frequency protections. Water
sealed ballast heater tank holding ballast heater

Transmission and distribution line

Overhead line of 3 phases, 4 wires is used. Single phase is used for branch line. The
conductor size has been selected on the basis of average load demand taken at the time of
survey and future extension of load has been also taken in consideration.

Management and organizational structure

This is a community based project. People do have deep concern to the project and are ready
to work for it. They have already formed 11 member users committee in the chairmanship of
Mr. Ram Bahadur Syangtang for the project. The anticipated level of community
participation in the MHP project is very high. The entrepreneurial sprit level was found fair.
The managerial, business skills of the community were found fair. The local people are no t
educated up to higher level but they have selected person for the operation of the plant. They
have send him for the training to acquire knowledge and operational skill for operation of the
plant. One plant manager and one operator has been selected for the operation of the plant.

Environmental Impact

In this project, there is no risk of flood exposure. The headrace alignments were in use since a
long time for irrigation purpose. So the negative environmental impact seems unlikely.

NEA Electrical Grid

The nearest grid point is Nau khande, which is at a distance of 5 km from the project site.
There seems no possibility of extension of NEA grid line within next 5 years.
 fund collection
S.N. Source         RS
1 VDC         40000
2 District development committee   400000
3 drinking water/women committee   38450
4 local collection   1342500
5 Alternative energy promotion center(AEPC)   1344644
6 Labour cost         1268237

S.N. Expenditure         RS
1 survey and technical expenditure   33000
2 administrative expenditure   125325
3 electrical equipment purchase   258713.5
4 organisation register   500
5 Transportation   9727
2725087.
6 machinery equipment   1
7 Miscellaneous   4733
1268237.
8 labour cost   7
9 bank मौज्दात (बैंक मौज्दात )   5000
10 cash मौज्दात (नगद मौज्दात )     8508
4438831.
  Total         3

Spare parts and tools

The technical details of the spare parts may vary depending upon the suppliers. It is
recommended to the suppliers to provide the spare part as required for their equipment. The
general list however has been provided here:

 Turbine bearing
 Turbine seals
 Gaskets for pipe
 Nuts and bolts
 Grease (1 kg)
 Bearing for the generator
 Control fuses (HRC fuse)
 Ballast load heater
 OBSERVATIONS AND FINDINGS
DISCHARGE MEASSUREMENT
Area Velocity method

This Method is based on the principle that for a fluid of constant density flowing through a
cross-section, the product of cross-sectional area and mean velocity will be constant that is
the discharge.

Q(m3/s)= Area(m2)x vmean(m/s)

Float Method:

Sn Dist travelled
(L)m Time sec Surface Velocity m/sec Mean Velocity m/sec
1 24 44.23 0.5426 0.35269
2 24 46.83 0.512 0.3328
3 24 44.7 0.537 0.349
4 24 42 0.571 0.371
5 24 46 0.522 0.339
6 24 42 0.571 0.371
7 24 42 0.571 0.371
8 24 39 0.615 0.399
9 24 38.7 0.62 0.403
10 24 41.63 0.576 0.374
  V= 0.366 m/s
The velocity is to be measured using the float method. The surface velocity of a smooth
section of stream is to be determined along with its average area. Different Floats are allowed
to pass through the section of measured length of the stream and the time taken is measured.
Then the surface velocity is calculated. TO obtain the true velocity, the surface velocity is to
be multiplied by correlation factor depending on the nature of the stream.

Taking Correction Factor for velocity =0.65

Width Depth(cm) area, A (avg)
(cm) Ai(cm2) cm2
D1 D2 D3 D4 D5 D6 D7 D8 D9 D1 D
0
for 3 6 8 7.5 7 7.5 8 8.5 5 3 6.35 508
w1=80
cm 525
for 2 5 9 9 8.5 7 9 8 7 5 6.95 597.7
w2=86
cm
for 5 5 8 9 10 11 9 7 4 2 7 525
w3=75
cm
for 5 10 12 11 9 8 7 3 3 2 7 469
w4=67
cm

So, Aavg= 525* 10-4 m2 = 0.0525 m2

So Estimated Discharge Q = Area x Velocity

= 0.366*0.0525

= 0.0192 m3/s

= 19.2l/s

The Salt Gulp Method

The ‘Salt gulp’ or the salt dilution method of flow measurement has been proved easy to
accomplish, accurate (< 17%) and reliable in a wide range of stream types. Using this method
stream flow can be measured in less than 10 minutes and very little equipment is needed. The
main device is conductivity meter. The calculations following take a little longer if done
manually. Disadvantage of this method is the cost of the meter. The probe is immersed, close
to the bed of the stream (not near the surface) or ideally at mid-depth. A bucket of heavily
salted water should be thrown into the stream. The 'cloud' of salty water in the stream starts to
spread itself out while travelling downstream. At a certain point downstream it will have
filled the width of the stream. The cloud will have a leading part which is weak in salt, a
middle part which is strong in salt, and a lagging part which is weak. Salt conducts
electricity, so the saltiness of the water can be measured with an electrical conductivity meter.
If the stream is flowing slowly, and has a small volume of water passing the meter each
second, it will take a long time for the cloud to pass. Since not much water is present, it will
not dilute the salt very much, so the electrical conductivity (which is greater the saltier the
water) will be high. lt is apparent, then, that low flows are indicated by high conductivity
measured in the cloud, and long cloud passing times.
 Observation Table
S.N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Tim 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85
e
2 2 2 2 2 2 6 11 9 7 5 4 3 3 3 2 2 2

2 2 2 2 2 2 3 11 12 7 5 4 4 3 3 3 2 2

2 2 2 2 2 2 6 13 10 7 5 4 3 3 3 2 2 2

2 2 2 2 2 4 6 6 6 5 5 4 4 3 3 2 2 2

14

12

10
Conductivity

0
0 20 40 60 80 100 120
Time
 Area Under the Curve.

So, Q= (m k-1)/A

Where

Q= Discharge in l/sec

m= mass of salt added in mg= 200g x 103

k=Conversion factor. At 22°C k-1=2.04x10-6 ohm-1 per mg per l

Then Q= 18 l/sec

HEAD MEASUREMENT
Water-filled tube

This method of head measurement is useful for low head sites, since it is cheap and
reasonably accurate. A Height marker is required. A person can act as a reference height if
necessary or the graded rods can be used for better results. Two or three separate attempts
must be made, so that you can make sure that your final results are correct and reliable. ln
addition the results should be cross-checked against measurements made by another method.

Nylon hose, either transparent or with transparent ends can be used. A hose diameter of
between 4 and 10 mm is convenient.
Sighting Meters

Hand-held sighting meters (also known as Clinometers or Abney levels) can measure the
angle of inclination of a slope. They can be very accurate if used by an experienced person.
They are small and compact, and sometimes include range-finders which save the trouble of
measuring linear distance. Since the method demands that the linear distance along the slope
is recorded, it can have the advantage of measure of the length of penstock pipe as well.
Sample Calculation:

Angle made with horizontal Slope distance Height

(α) in degree (s) in metre (H=s*sinα) in metre
42 15.67 10.48
16 6.5 1.79
37 25.2 15.16
37 25.2 15.16
41.3 27.9 18.4
20.5 24.5 8.576
34.2 25.2 14.15
29.8 28.3 14.05
28.7 38.4 18.43
35 20.7 11.29
29.5 19.8 12.58
19 9.5 3.09
36.5 17.5 10.4
39 16.24 10.21
40.7 16.25 10.59
33 18.2 9.9
Total 184m

SELECTION OF TURBINE
Taking ,
The discharge =22l/s considering percentage exceedance Q92%.
Gross Head =180; So Net head = 162m considering 10% head loss.
Taking Turbine efficiency = 75%, other mechanical efficiency = 85%, generator
efficiency= 90%.

Taking above considerations, Net efficiency ≅ 50%

So
Turbine output power =ηturbine *Q*H/100 KW
= 0.75*22*162/100
= 26.73 KW
Plant Output = η* Q*H/100 KW
=0.5*22*162/100
=17.8 Kw

The nomogram is used in order to select the turbine best suited for our purpose.

Choosing a turbine shaft speed of 1500 rpm for direct drive between turbine and 5OHz 4-pole
generator.
Constrained in the boundary marked by shaft power of 26.73KW, net head 162m, and a
turbine speed of 1500 rpm and taking percentage exceedance of 92% , the best suited
turbine from the nomogram chart is single jetpelton turbine.

Calculation of Specific speed:

calculated specific speed will,
Ns =N*(power in H.P)0.5/H5/4
= 1500*(17.8/0.746)0.5/1625/4
= 12.67rpm

Ideal Diameter or the runner for gearing ratio 1;

38 √ H net 38 162
Dideal = = √ = 0.32244 m = 322.44mm
RPM 1500
 0.54 √ Q
Diameter of jet for different no of jets d jet =
H net0.25 x √ n jet
No. of jets 1 2 3 4
Djet 22.45 15.8749 12.96 11.225
Runner diameter
D=6*Djet 134.7 95.2494 77.76 67.35
D=20*Djet 449 317.498 259.2 224.5
Notch width
> Djet+3 mm >25.45 mm >18.8749mm >15.96 mm >14.225 mm

So we can select, No of Jets =1;

Conformed Form the above table, we can select No of jets = 1

Runner dia =322.44 mm

Selection Of mechanical Transmission system:

Drive systems comprise the generator shaft, turbine shaft, the bearings which support those
shafts, couplings to connect shafts, any extra bearings, pulleys, belts, gearboxes or other
components required change speed or orientation of the shafts. The function of the drive
system is to transmit power from turbine to the generator at the correct speed for the
generator and in a suitable direction.
The drive system must carry the required loads and also the foundation must be able to bear
the total load imposed on it.
 

As Turbine Speed =1500 rpm, Generator speed = 1500 Rpm so, we do not require any
speed changing mechanism, So to avoid the losses imposed in other transmission
systems like belt drive, we choose the Direct Coupling mechanism with rubber glands
coupling.
Features of Direct coupling
 Compact and simple
 Efficiency approaches 100%.
 No additional loads on bearings.
 Both turbine and generator can be bolted to concrete foundation metal adjustable
packing with slides is required.
 Alignment of shafts must be correct to in order to prevent failure of coupling or
bearings.
 Flexible in-line coupling is needed because shaft alignment is never perfect.
 No speed change option is available.
 

SELECTION OF GOVERNING SYSTEM

 
Governors are the devices used to control the speed of the turbine –generator system. It
should be selected in order to ensure proper operation of the mechanical or electrical end use
machinery.
Previously, governing devices for hydro Power plants adjusted the flow of water through the
turbine to vary the water power input on the plant. But these days, Electronic Load
Controllers are often used which works by making total power consumed from the generator
constant. The unused power is given to the dummy load and is dissipated as heat. It senses
the generator frequency and reacts by increasing or decreasing the firing angle of the
thyristor.

Figure: ELC with ballast load

Selecting Electronic Load Controller (ELC) as it is best for micro hydros considering
synchronous generator used. We select Thyristor fired type ELC.

Then

Generator size = 17.8KW

Rated voltage of heater = 230 V
Voltage across the terminals of ballast load = 220V
Temperature of entering water = 25° C
Temperature of outgoing water = 50° C
Allowable temperature rise = 25° C
Specific heat of water = 4200J/Kg/K
Now we need to design the ballast load such that when all the loads are switched off, the
ballast can safely dissipate the generated power without causing excessive temperature rise or
damage.
Let us choose 5KW water heater elements i.e two numbers of 2.5KW sub-elements in
parallel.
Resistance of 5KW element;
(voltage)2
Relement =
power
= (230)2/5000
= 10.58 Ω
When full load is diverted to the ballast, voltage across is only 220V.
Power dissipated in each 5KW element;
( voltage ) 2
Power dissipated =
Resistance
= (220)2/10.58
= 4574.66w
= 4.57KW
Now, consider 4such heating elements;
total power dissipated = 4*4.57
=18.29KW
(18.29−17.8)
Percentage oversize = *100
17.8
= 2.75%<15% which is satisfied.
Resistance of one sub-element = 10.58*2
= 21.16 Ω
As there are 4 elements, total number of sub-elements = 8
21.16
Effective resistance of 8 sub-elements in parallel =
8
= 2.645Ω

Power that can be dissipated by 2.6 45Ω resistance at 220V = (2202)/2.645

= 18.29KW

SELECTION OF GENERATOR

Two types of ac generator are suitable for use in a micro-hydro powers. These are
synchronous generators (or alternators) and induction generators.
Induction generators uses induction motor as a generator but are used in small micro-hydro
schemes(<10KW) ranges. They are they are easily and cheaply available as motors, simply
constructed and repaired, reliable, require little maintenance and also can withstand 100%
overspeed.
Induction generators are easily used as generators when connected to an existing supply
system (grid) and when used in a stand-alone application such as an isolated micro-hydro
scheme they require fitting with excitation capacitors. They require a voltage plus speed
governing system known as Induction Generator Controller.
Unlike Induction Generators, the synchronous generators are used in larger systems. They
have separate excitation system. The excitation generator is supplied by the excitation system
(Generally an AVR) and the output of the generator is given to the main generator field using
the rotating diode to convert it to DC. Though higher efficiency, better voltage and frequency
regulation ability as well as synchronization capabilities, it has more maintenance
requirements.

Generator sizing:

Calculated Power output P=26.73KW

Considering Power factor = 0.75

Generator size will be P1=P/PF =26.73/0.75 =35.64 KVA

Considering the better lifetime and performance characteristics and allowance for tansmission
losses, as well as considering reactive power consumption use with ELC it should be
overrated 60%

P3=35.64 * 1.6 = 57.024 KVA

So we Select Generator of 60KVA (closest available off the shelf generator).

Excitation System
In a synchronous generator, the main field winding should be provided with current in order
to generate the required magnetic field. The output voltage of the generator can regulated by
varying the field current. For this purpose we require a proper excitation system. The
Brushless excitation system is selected for our purpose. In this type of excitation system, we
have a small synchronous generator attached to the main generator. The excitation generator
has its field winding as its stator. The field is supplied by regulated DC power supply by an
AVR which senses the Generator terminal output voltage. The Main field is supplied through
rotating diodes which is mount to generator shaft supplied by the rotor winding of the excitor
generator. This avoids the requirement of any carbon brushes commutator/ sliprings .
We take Brushless excitation with an AVR. The mounting of the AVR is done in a separate
panel to avoid the possible moisture and vibrations.

COST ESTIMATION
Estimated Cost Categorisation:

S.N. Description of items Amount

1 Installation supervision and 120000
commissioning charge
2 Cost of civil construction 1850000
3 Cost of mechanical component 1262015
4 Cost of electrical component 1062015
5 Transportation cost 60755
6 Other Costs 179000
  Total 45,33,785

Investment Capital categorization:

Sn Particulars Amount
1 Expexted Subsidy from Govt. 1440000
2 Loan Form Bank 1500000
3 Labour Contribution by locals 900000
4 Investment from Locals 693785
Total Investment 45,33,78
5
 TARRIF DESIGN
Load Distributions:

Considering the following loads will probably incurr to the plant throughout the year:

S.N. Description Operating Time Running Power consumed Energy

Hours (KW) Consumed
KWHr
1 Lighting Loads 6pm-12pm; 4am- 9 12 108
7am
1 Saw mill 10 am to 5 pm 7 8 56
2 Rice mill 12am to 6 pm 6 6 36
3 Battery charging 10am to 6 pm 8 2 16
4 Other Residential 6 am- 12pm 18 3 54
Loads
Energy Consumed Per 270
Day

Total Energy Consumed per day= 270 KWHr

Total Energy Generated per day =24Hr *18.48KW

=443.52 KWHr

Considering outage of 1 month per year for maintainence and failures:

270
EnergyConsumed ∗11
Plant Factor = = 443 = 0.553
EnergyGenerated
12

1500000

Investment Excluding Subsidy From Government = Rs 15,00,000

This amount must be considered to be returned in payback period of 6 yrs with Rate of return
of 10%

i∗(1+i)n 1500000∗0.1∗(1+0.1)6
So Annual Cost should be A =P¿ =
(1+i)n −1 (1+0.1)6−1

=Rs 3,44,411/-

Operation and maintainance cost = 6% of Total Insvestment = 3,62,700/-

Total Annual Cost =Rs7,07,100/-

Now

We have, peak Total Connected loads of = 31 Kw

Total Annual cost 707100

So per watt cost should be = = =Rs 1.9 per Watt per month
W ∗12 31000∗12
Considering

Rs 2/- Per Watt, Yearly income =2*31000*12= 7,44,000/-

Now Yearly Welfare Fund savings=7,44,000-7,07,100=Rs 36,900/-