Escolar Documentos
Profissional Documentos
Cultura Documentos
05
SHPP/GTZ
NOTICE
The earlier version of these hydropower Design Aids had been prepared to provide a basis for microhydropower consultants to undertake calculations and prepare drawings as per the requirements of
Alternative Energy promotion Centre (AEPC) of the Government of Nepal. The tools in this version
(version 2006.05) were amended to fulfill the minimum requirements of standard micro and mini
hydropower project feasibility studies. It is expected that the use of these Design Aids will result in a
standard methodology for calculating and presenting MHP designs.
This manual and any examples contained herein are provided as is and are subject to change without
notice. Small Hydropower Promotion Project (SHPP/GTZ) shall not be liable for any errors or for
incidental or consequential damages in connection with the furnishing, performance, or use of this manual
or the examples herein.
Small Hydropower Promotion Project (SHPP/GTZ). All rights reserved.
All rights are reserved to the programs and drawings that are included in the MHP Design Aids.
Reproduction, adaptation or translation of those programs and drawings without prior written permission of
SHPP/GTZ is also prohibited.
Micro-hydropower Design Aids (v 2006.05) is a shareware and can also be downloaded from
www.entec.com.np . Permission is granted to any individual or institution to use, copy, or redistribute the
MHP Design Aids so long as it is not sold for profit. Reproduction, adaptation or translation of those
programs and drawings without prior written permission of SHPP/GTZ is prohibited.
Published by:
Small Hydropower Promotion Project (SHPP/GTZ)
Pulchowk, Lalitpur, Nepal
PO Box 1457, Kathmandu, Nepal
Tel: 977 1 5009067/8/9
Fax: 977 1 5521425
Web: http://www.entec.com.np
Email: shp@gtz.org.np
Author:
Page: ii
SHPP/GTZ
PREFACE
This set of hydropower design tools is an updated version of Micro-hydropower Design Aids which was
prepared by Small Hydropower Promotion Project (SHPP/GTZ) during its collaboration with Alternative
Energy Promotion Centre (AEPC/ESAP) from 2002 to 2004. It is a complete set of tools consisting of
typical AutoCad drawings, typical Microsoft Excel spreadsheets and a users manual. An electronic
version of earlier tools was officially distributed by AEPC/ESAP for using up to feasibility study levels of its
subsidized micro-hydropower schemes up to 100kW.
German Development Cooperation (GTZ) has been cooperating with the Kingdom of Nepal for more than
four decades. During this period its bilateral Technical Cooperation covered a broad range of sectors
including agriculture, livestock, rural development, forestry, energy, credit, industry, vocational training,
urban development, education and health. Small Hydropower Promotion Project was established in 1999
as its bilateral Technical Cooperation on energy sector. Since then this project has been providing
technical and logistic services to small hydropower stakeholders within Nepal through Entec AG of
Switzerland as an implementing consultant of this project.
Since its establishment in 1999, SHPP/GTZ has been providing its services to hydropower stakeholders.
Although its main mandate is to provide technical and logistic supports to small hydropower projects in
Nepal within the range of 100kW to 10MW, SHPP/GTZ has also been backstopping hydropower project
below 100kW. The overwhelming positive feedbacks from micro and small hydropower stakeholders on
these tools and continuous update and distribution of these tools are the examples of its concern on the
holistic approach of sectorial development of hydropower in Nepal. This version of the design aids
includes three additional spreadsheets and enhanced utilities especially useful for mini hydropower project
component designs. Since these tools were verified with real project studies, I personally found them very
useful for the stated design works.
Irrespective of the sizes and locations, all hydropower schemes have a common feature using potential
energy of water for generating electricity. Therefore, use of all the tools except the spreadsheet on
hydrology can also be used for micro and mini hydropower projects outside Nepal. Moreover, some
spreadsheets and drawings can also be small and even large hydropower project designs. These tools
have also been used in some small hydropower projects in Vietnam and micro hydropower projects in
Afghanistan.
I would like to thank Entec AG, Switzerland and German Development Cooperation, Nepal for their
support to make this publication happen. My special thank goes to Mr. Pushpa Chitrakar, Engineering
Advisor of SHPP/GTZ, for his devotion of making such a useful complete set of utility package for micro
and mini hydropower project designs. I would also like to extend my sincere thanks to AEPC/ESAP for
their contributions to the development of these Design Aids. The contribution of all SHPP/GTZ team
members for their continuous support on the development of these design aids is highly appreciated.
I do hope that this Micro-hydropower Design Aids would fill the gap that has been felt by all the micro and
mini hydropower stakeholders and will be able to contribute to the hydropower sector.
Sridhar Devkota
Project Manager
SHPP/GTZ
Page: iii
SHPP/GTZ
ACKNOWLEDGEMENTS
Thanks for using the Micro-hydropower Design Aids (version 2006.05). Micro-hydropower
Design Aids is a complete set of tools consisting of typical AutoCad drawings, typical Microsoft
Excel spreadsheets (a workbook) and a users manual (this manual) recommended for use in the
feasibility study of micro and mini hydropower schemes. Although these tools were mainly
prepared based on the prudent practices of Nepali micro and mini hydropower scheme designs,
it is expected that the use of these Design Aids helps enhancing the overall quality of hydropower
sector within Nepal and abroad. All spreadsheets except Hydrology can also be used for mini
and small hydropower projects outside Nepal. However, the title of these tools in this version is
not changed.
Why I Prepared the Design Aids
I approached this project with one goal in mind. To write a one-step Micro-hydropower Design
Aids that would appeal to all Nepali micro-hydropower stakeholders. That is a fairly ambitious
goal. But based on the feedback I received from all the stakeholders, I think I have been
successful. In addition to updating the existing tools for use in mini, micro and small hydropower
projects, spreadsheets for calculating anchor block calculation and design, machine foundation
design, loan payback cash flow, etc, are added in this version. These additional tools are
especially useful for mini and small hydropower projects. Interactive diagrams to most of the
spreadsheets are added in this version.
Microsoft Excel is the present market leader, by a long shot, and it is truly the best spreadsheet
available. Excel lets you do things with formulas and macros (Visual Basic for Application) that
are impossible with other spreadsheets. Similarly, Autodesk AutoCad has been the best and
suitable tool for creating digital drawings. Since most of the hydropower stakeholders are familiar
with these application software, I have prepared these tools on these application software
platforms.
Although the above mentioned software are popular amongst all the micro-hydropower
stakeholders, it is a safe bet that only about five percent of Excel and AutoCad users in Nepali
hydropower sector really understand how to get the most out of these software. With the help of
these Design Aids, I attempt to illustrate the fascinating features of these software (especially
Excel) and nudge you into that elite group.
I have noticed that there are very few complete technical tools and books related to micro and
small hydropower design available in the market. A single set of tools for all the calculations is
not yet available. Moreover, the outcome of most of these tools are not adequately tested and
verified. Most of the good software have none or only poorly illustrated manuals. The combined
outcome may produce poor quality feasibility studies which lead to improper implementation
decision. To overcome these dangers, I have prepared the Design Aids along with this manual.
Electronic version of the Design Aids (an Excel workbook), 15 AutoCad drawings and this
manual in Acrobat PDF format are presented on the attached CD ROM.
This set of Design Aids (v 2006.05) is a shareware. It would not have been possible for me to
write this Design Aids package without the encouragement from German Development
Cooperation, Nepal; Entec AG, Switzerland and of course, Mr. Sridhar Devkota, the Project
Manager, Small Hydropower Promotion Project. I would also like to thank my colleague Mr.
Girish Kharel for his tireless assistance and valued suggestions on composition and presentation.
Page: iv
SHPP/GTZ
: Windows 98/2000/NT/XP
CPU
: 486/333MHz
RAM
: 128MB
Display
CD ROM
HD
: 10 MB (approximately)
SHPP/GTZ
schemes had thirteen typical spreadsheets. Some additional spreadsheets have been presented
to cater mini and small hydropower design needs. These spreadsheets provide users to
estimate hydrological parameters; design civil, mechanical and electrical components and
analyze financial robustness of the perspective micro and mini hydropower schemes in Nepal.
Part III: Users Manual
This manual (also in Adobe Acrobat PDF format) illustrates aspects of using the presented
drawings and spreadsheets; and stepwise calculations covering all technical and non technical
(costing and financial) components of hydropower schemes.
Download and Reach Out
Electronic files included on the attached CD can also be downloaded from www.entec.com.np.
Updates will also be posted on this site. Preparation of the Design Aids is a continuous process.
I am always interested in getting feedback on these Design Aids. Therefore, valuable
suggestions and feedbacks are expected from all the stakeholders/users so that the overall
quality of the hydropower sector is enhanced. Any suggestion and feedback can directly be sent
to my email pushpa.chitrakar@gtz.org.np. Sharing of hydropower related information regarding
advanced options beyond this design aids is also expected.
Pushpa Chitrakar
Engineering Advisor
SHPP/GTZ
Page: vi
SHPP/GTZ
TABLE OF CONTENTS
Page No.
NOTICE
II
PREFACE
III
ACKNOWLEDGEMENTS
IV
TABLE OF CONTENTS
VII
1.
INTRODUCTION
1.1
GENERAL
1.2
1.3
1.4
1.5
1.6
5
5
6
6
7
7
7
7
7
8
8
9
10
11
1.7
INSTALLATION DIRECTORY
11
DISCHARGE MEASUREMENT
12
2.1
GENERAL
12
2.2
12
2.3
CALCULATION AT SITE
13
HYDROLOGY
15
3.1
GENERAL
15
3.2
HYDROLOGICAL DATA
15
3.3
16
3.4
18
3.5
GENERAL RECOMMENDATIONS
19
Page: vii
3.6
SHPP/GTZ
20
HEADWORKS
23
4.1
23
4.2
GENERAL RECOMMENDATIONS
4.2.1 Weir
4.2.2 Intake
4.2.3 Intake Trashrack
24
24
24
24
4.3
24
26
29
HEADRACE/TAILRACE
32
5.1
GENERAL
32
5.2
GENERAL RECOMMENDATIONS
5.2.1 Canal
5.2.2 Pipe
32
32
32
5.3
33
33
33
36
SETTLING BASINS
39
6.1
39
6.2
40
6.3
GENERAL RECOMMENDATIONS
6.3.1 Gravel Trap
6.3.2 Settling Basin
6.3.3 Forebay
40
40
41
41
6.4
42
42
43
43
43
47
7.1
GENERAL
47
7.2
GENERAL RECOMMENDATIONS
47
7.3
47
47
48
7.4
51
51
7.5
55
55
TURBINE SELECTION
59
Page: viii
10
11
12
13
14
SHPP/GTZ
8.1
GENERAL
59
8.2
GENERAL RECOMMENDATIONS
59
8.3
60
61
9.1
GENERAL
61
9.2
61
61
61
9.3
GENERAL RECOMMENDATIONS
9.3.1 Sizing and RPM of a Synchronous Generator:
9.3.2 Sizing and RPM of an Induction Generator:
62
62
63
9.4
63
63
64
66
MACHINE FOUNDATION
68
10.1
68
10.2
EXAMPLE
68
72
11.1
72
11.2
GENERAL RECOMMENDATIONS
72
11.3
72
72
77
12.1
GENERAL
77
12.2
77
12.3
77
77
80
13.1
80
13.2
80
13.3
80
80
81
UTILITIES
83
14.1
83
83
83
84
INTRODUCTION
14.1.1 Uniform depth of a rectangular or trapezoidal canal
14.1.2 Payment of loan for different periods (monthly, quarterly and yearly)
14.1.3 Power calculations
Page: ix
SHPP/GTZ
15
85
85
86
REFERENCES
87
DRAWINGS
XVII
LIST OF FIGURES
Figure 1.1: A typical Micro Hydro Settling Basin Drawing .................................................................4
Figure 1.2: A typical Small Hydro Settling Basin Drawing .................................................................4
Figure 1.3: Iterative process .................................................................................................................6
Figure 1.4: Activation of iteration (Tools => Option =>Calculations..................................................6
Figure 1.5: Enabling macros and macro security ...............................................................................6
Figure 1.6: Cell formula incorporated in a cell note............................................................................7
Figure 1.7: A cell note presenting typical values of Mannings n for different surfaces ..................8
Figure 1.8: Colour coding of cell texts.................................................................................................8
Figure 1.9: Different categories of inputs. ...........................................................................................9
Figure 1.10: Different categories of inputs. .........................................................................................9
Figure 1.11: Design Aids Menu and Toolbar .....................................................................................10
Figure 1.12: Typical interactive diagram of Side Intake....................................................................11
Figure 2.1: Discharge calculations by salt dilution method .............................................................14
Figure 3.1: Hydrology..........................................................................................................................15
Figure 3.2: Hydrological Data and MHP .............................................................................................15
Figure 3.3: MIP Regions ......................................................................................................................16
Figure 3.4: MIP model .........................................................................................................................17
Figure 3.5: Need of interpolation for calculating mean monthly coefficient ...................................17
Figure 3.6: Effect of interpolation on mean monthly flows ..............................................................18
Figure 3.7: Hydest Model ....................................................................................................................19
Figure 3.8: Flow chart of Hydrology spreadsheet .............................................................................20
Figure 3.9: Typical example of a hydrological parameters calculation spreadsheet Hydrology22
Figure 4.1: Trashrack parameters ......................................................................................................25
Figure 4.2: Flow chart for trashrack calculations..............................................................................25
Figure 4.3: Side intake parameters ....................................................................................................26
Figure 4.4: Flow chart for side intake calculations ...........................................................................27
Figure 4.5: An example of side intake calculations ..........................................................................28
Figure 4.6: Parameters and flow chart of drop intake design ..........................................................29
Figure 4.7: An example of drop intake...............................................................................................31
Figure 5.1: Flow chart for canal design .............................................................................................34
Figure 5.2: An example of canal design.............................................................................................35
Figure 5.3: Illustrated canal type and their dimensions....................................................................36
Figure 5.4: Flow chart for pipe design ...............................................................................................37
Figure 5.5: An example of headrace pipe design..............................................................................38
Figure 6.1: Typical section of a settling basin...................................................................................39
Figure 6.2: An ideal setting basin.......................................................................................................40
Figure 6.3: Flushing pipe details ........................................................................................................43
Figure 6.4: Typical example of a settling basin (Settling basin, spilling and flushing). .................45
Figure 6.5: Typical example of a settling basin (Gate and rating curve). ........................................46
Figure 6.6: Typical example of a settling basin (forebay and dimensioning)..................................46
Figure 7.1: Flow diagram of penstock design ...................................................................................48
Figure 7.2: Input required for penstock and power calculations .....................................................49
Figure 7.3: Output of penstock and power calculation spreadsheet. ..............................................50
Page: x
SHPP/GTZ
LIST OF TABLES
Table 1.1: Summary of Micro Hydropower Drawings ........................................................................3
Table 1.2: Summary of Small Hydropower Drawings ........................................................................3
Table 1.3: Summary of Spreadsheets ..................................................................................................5
Table 2.1: Input parameters for Salt Dilution Method .......................................................................12
Table 2.2: First set conductivity reading for Salt Dilution Method (Example).................................12
Table 2.3: Data Input (partial) .............................................................................................................13
Table 3.1: MIP regional monthly coefficients ....................................................................................16
Table 3.2: Standard normal variants for floods.................................................................................19
Table 4.1: Drop intake and upstream flow .........................................................................................29
Table 6.1: Settling diameter, trap efficiency and gross head ...........................................................41
Table 7.1: Summary of penstock thickness and corresponding maximum permissible static head
.......................................................................................................................................................50
Table 7.2: Summary of forces.............................................................................................................53
Table 8.1: Turbine specifications .......................................................................................................59
Table 8.2: Turbine type vs. ns .............................................................................................................59
Table 9.1: Selection of Generator Type.............................................................................................62
Table 9.2: Generator rating factors ....................................................................................................62
Table 11.1: ASCR specifications ........................................................................................................72
Table 11.2: Rated current and voltage drop calculation ...................................................................72
Table 13.1: Per kilowatt subsidy and cost ceiling as per AEPC.......................................................80
Page: xi
SHPP/GTZ
Page
.................................... D-ii
.................................... D-iii
.................................... D-iv
.................................... D-v
.................................... D-vi
....................................... D-vii
..................................... D-viii
.................................... D-ix
.................................... D-x
.................................... D-xi
........................................ D-xii
........................................ D-xiii
........................................ D-xiv
........................................ D-xv
........................................ D-xvi
Page
Title / Remarks
Project Location, District Map & Catchment Area
Project Layout, sheet 1 of 2, Plan
Project Layout, sheet 2 of 2, Profiles
Weir, Intake and Gravel Trap, sheet 1 of 3, plan and sections
Weir, Intake and Gravel Trap, sheet 2 of 3, plan and sections
Weir, Intake and Gravel Trap, sheet 3 of 3, plan and sections
Settling Basin, sheet 1 of 2, plan and sections
Settling Basin, sheet 2 of 2, plan and sections
Plan and Profile and Typical Sections/Similar for penstock alignment
Anchor Blocks, sheet 1 of 2
Anchor Blocks, sheet 2 of 2
Saddle Support
Powerhouse Plan and Sections
Geological Mapping, sheet 4 of 4
Single line diagram
Page: xii
D-xviii
D-xix
D-xx
D-xxi
D-xxii
D-xxiii
D-xxiv
D-xxv
D-xxvi
D-xxvii
D-xxviii
D-xxix
D-xxx
D-xxxi
D-xxxii
1.
SHPP/GTZ
INTRODUCTION
1.1 GENERAL
This set of Micro-hydropower1 Design Aids is a complete set of feasibility level hydropower design
tools consisting of typical AutoCad drawings, typical Microsoft Excel spreadsheets and a users
manual recommended for micro and mini hydropower schemes. An earlier digital version of the set
was published as a part the publication of Alternative Energy promotion Centre (AEPC) of The
Government of Nepal2 (ISBN 99933-705-5-X) and has officially been recommended for its
subsidized micro-hydropower schemes in Nepal up to 100kW.
The micro-hydropower Design Aids were prepared to provide a basis for consultants to undertake
calculations and prepare drawings as per the requirements set aside by the procedural guidelines of
AEPC-the Government of Nepal. Since most of the stakeholders are familiar with Autodesk AutoCad
(2000 or later) and Microsoft Excel (XP or later) application software, the Design Aids were prepared
based on these software to make them simple and user friendly. During the preparation of these
Design Aids, special efforts were made so that the skills and knowledge of practicing stakeholders
such as consultants, manufacturers and inspectors are further enhanced by this Design Aids.
This design aids are updated version of the previous design aids and suitable for designing mini and
small hydropower schemes. Update, addition and publication of the design aids are the symbols of
Small Hydropower Promotion Project(SHPP/GTZ)3 SHPPs continuous assistance and support to the
Nepali hydropower sector.
The Design Aids consist of a set of fifteen typical drawings, a workbook with twenty-five typical
spreadsheets and a users manual for procedural guidance. This set of design aids also covers all
aspects recommended by AEPC guidelines for its subsidized micro-hydropower schemes. The
Design Aids provide users to estimate hydrological parameters; design civil, mechanical and
electrical components and analyze financial robustness of the prospective micro hydropower
schemes in Nepal. Procedural guidelines, detailed step by step calculations and guidelines for using
the presented spreadsheets are presented in this users manual. A copy of this manual in Acrobat
PDF file format is included in the bundled CD. The Design Aids are distributed in template/read-only
formats so that the original copy is always preserved even when the users modify them.
The Design Aids were originally prepared for micro hydropower schemes up to 100kW. Since there
are many common approaches and features in all hydropower projects, these spreadsheets were
modified to suit mini and small hydropower design requirements as well. Spreadsheets on
Hydrology are intended for Nepali micro hydropower schemes only. Spreadsheets on Cost&Benefits
and FinancialAnalyses are intended to serve micro-hydropower schemes outside Nepal too (refer to
Table 1.2).
Preparation and use of the Design Aids is a continuous process. SHPP/GTZ has been continuously
enhancing the Design Aids and this update (version 2006.05) is the outcome of SHPPs efforts in
hydropower sector development in Nepal. Therefore, valuable suggestions and feedbacks are
expected from all the stakeholders/users so that the overall quality of the micro hydro sector is
enhanced. Any suggestion and feedback can directly be sent to pushpa.chitrakar@gtz.org.np .
In Nepal, hydropower projects up to 100kW are termed as micro hydropower projects. Projects within 100kW to 1000kW are termed as
mini hydropower projects. 1000kW to 10,,000kW are termed as small hydropower projects. Beyond this, they are termed as large
hydropower projects.
2
Alternative Energy Promotion Centre (AEPC) is a Nepal Government organization established to promote alternative sources of energy in
Nepali rural areas. MGSP of AEPC-ESAP is promoting Nepali micro-hydropower schemes up to 100kW.
3
Small Hydropower Promotion Project is a joint project of the Government of Nepal, Department of Energy Development (DoED) and
German Technical Cooperation (GTZ). Since its establishment in 1999, this project has been providing its services to sustainable
development of small hydropower projects in Nepal (100kW to 10MW) leading to public private participation and overall rural development.
It has also been providing technical support and backstopping to Nepali micro-hydropower stakeholders including AEPC. Entec AG of
Switzerland is the implementing consultant of this project.
Page: 1
SHPP/GTZ
Page: 2
SHPP/GTZ
5. Basic drawing elements such as a title box with adequate information and controlling
signatories; scale; etc are presented.
6. All drawings with standard layouts for printing.
The dimensions and geometries of the presented drawings should be amended according to the
project details. A set of all the drawings are presented in the appendix. For an example, a typical
drawing of a settling basin is presented in Figure 1.1. The MHP drawings that are presented are
listed in Table 1.1.
5
6
7
8
04 Headrace
05A Gravel Trap
05B Settling Basin
06 Headrace Canal
07 Forebay
10
11
08 Penstock Alignment
09
Anchor
&
Saddle
Blocks
10 Powerhouse
11 Machine foundation
12 Transmission
13 Single line diagram
12
13
14
15
Remarks
General layout of project components except the transmission and
distribution components.
A general plan of headworks including river training, trashrack, intake,
gravel trap and spillway.
A longitudinal section along water conveyance system from intake to
headrace, two cross sections of weir for temporary and permanent weirs
respectively and a cross section of a spillway.
A general plan, a cross section across a permanent weir and a cross
section of a drop intake.
A longitudinal headrace profile showing different levels along it.
A plan, a longitudinal section and two cross sections.
A plan, a longitudinal section and two cross sections.
Two cross sections for permanent lined canal and one for temporary
unlined canal.
A plan, a longitudinal section, two cross sections and penstock inlet
details.
A longitudinal section of penstock alignment.
Plans and sections of concave and convex anchor blocks and a saddle.
A plan and a section of a typical powerhouse.
A plan and three sections of a typical machine foundation.
A single line diagram if a transmission/distribution system.
A single line diagram showing different electrical components.
Drawing no
7.D.np.5133/01/
10A01
10A02
10A03
20A01
20A02
20A03
20A04
20A05
30A01
40A10
40A11
40A12
50A02
60A04
70A01
Title / Remarks
Project Location, District Map & Catchment Area
Project Layout, sheet 1 of 2, Plan
Project Layout, sheet 2 of 2, Profiles
Weir, Intake and Gravel Trap, sheet 1 of 3, plan and sections
Weir, Intake and Gravel Trap, sheet 2 of 3, plan and sections
Weir, Intake and Gravel Trap, sheet 3 of 3, plan and sections
Settling Basin, sheet 1 of 2, plan and sections
Settling Basin, sheet 2 of 2, plan and sections
Plan and Profile and Typical Sections/Similar for penstock alignment
Anchor Blocks, sheet 1 of 2
Anchor Blocks, sheet 2 of 2
Saddle Support
Powerhouse Plan and Sections
Geological Mapping, sheet 4 of 4
Single line diagram
Page: 3
SHPP/GTZ
Page: 4
SHPP/GTZ
Name
Discharge
Hydrology
Side Intake
4
6
Bottom Intake
Canal
7
5
Pipe
Settling Basin
Penstock
9
10
11
AnchorLoad
AnchorBlock
Turbine
12
Electrical
13
14
Machine
Foundation
Transmission
15
Load Benefit
16
Costing
Financial
Utilities
1724
&
Area of coverage
Chapter 2: Computation of river discharge from Salt dilution method.
Chapter 3: Hydrological parameters calculations based on MIP and
Hydest methods (Regression Methods)
Chapter 4: Design of side intakes including coarse trashrack, flood
discharge and spillways.
Chapter 4: Design of bottom intake including flood discharges.
Chapter 5: Design of user defined and optimum conveyance canals with
multiple profiles and sections.
Chapter 5: Design of mild steel/HDPE/PVC conveyance pipes.
Chapter 6: Design of settling basins, gravel traps and forebays with
spilling and flushing systems with spillways, cones and gates.
Chapter 7: Design of penstocks with fine trashrack, expansion joints and
power calculations.
Chapter 7: Calculations of forces on anchor blocks.
Chapter 7: Design of anchor block.
Chapter 8: Selection of turbines based on specific speed and gearing
ratios.
Chapter 9: Selection of electrical equipment such as different types of
generators, cable and other accessories sizing.
Chapter 10: Design of machine foundation.
Uses
Micro/small
Micro/ small
in Nepal
All sizes
Micro/small
All sizes
All sizes
All sizes
All sizes
All sizes
All sizes (2D)
All sizes (2D)
Micro
Micro
Micro
Micro
Micro
All sizes
Design of anchor blocks and saddles are site and project specific. The presented anchor block
spreadsheets are based on two-dimensional calculations and are useful for penstock aligned in
straight lines without any horizontal deflection.
Background information and main features of the presented spreadsheets are:
1.6.1 Flow chart notations
Standard flow chart notations are used to describe program execution flows. Following notations are
mostly used:
Start and End
Input
Processing formulas and output
Processing and output from other sub routine
Page: 5
SHPP/GTZ
Conditional branching
Flow direction
1.6.2 Iterative Processes
The spreadsheets are designed to
save
tedious
and
long
iterative/repetitive processes required
for calculations.
Manual repetitive
processes are the main source error
generating and they are also time
consuming factors. A typical repetitive
process is presented in Figure 1.3.
Y =f(X): X=f`(Y)
Assume Xo
Is
Yes
End
e=<|Yn+1 Yn|
No
X=X+h
Page: 6
SHPP/GTZ
Page: 7
SHPP/GTZ
Figure 1.7: A cell note presenting typical values of Mannings n for different surfaces
1.6.9 Cell Text Conventions
Three different colour codes are used to distinguish three different cell categories. A typical example
of colour coding of cells is presented in Figure
1.8. The colours and categories of these cells
are:
Blue cells: These cells represent
mandatory input cells. These cells are
project dependant cells and project
related actual inputs are expected in
these cells for correct outputs. The
mandatory input includes the name of
project, head, discharge, etc. Some of
these cells are linked.
Figure 1.8: Colour coding of cell texts
Red cells: These cells are optional input cells. Standard values are presented in these cells.
Values in this type of cells can be amended provided that there are adequate sufficient
grounds to do so. It is worth noting that care should be taken while changing these values.
Typical optional values / inputs are the density of sediment, sediment swelling factor,
temperature of water, etc.
Black cells: The black cells represent information and or output of the computations. For the
sake of protecting accidental and deliberate amendment or change leading to wrong outputs,
these cells are protected from editing.
1.6.10 Types of inputs
According to the nature of inputs, the inputs are further categorized into the following three groups:
Page: 8
SHPP/GTZ
1. User or project specific inputs: The input variables that totally depend on the user and or
the project are categorized as the user or project specific inputs. The programs do not restrict
on or validate the values of such inputs. The name and gross head of the project are some of
the examples that fall on this category. The velocity through orifice (Vo) in the example
presented in Figure 1.9 can have any value hence it is a user specific input.
2. Prescribed Input: Some of the inputs have some standard values for standard conditions.
The programs list using such values and give choices for the user to select. However, the
programs do not restrict on or
validate
such
variables.
These inputs are termed as
prescribed inputs.
For
example in Figure 1.9, with the
help of a pull-down menu,
Mannings coefficients for
different types of surfaces are
listed for selection. This will
greatly reduce the need for
referring external references.
However, any specific values
for specific need can be
entered into this type of cells.
Figure 1.9: Different categories of inputs.
3. Mandatory Input: Some inputs can only have
specific values and the programs need to validate
such values for proper computations. These values
are termed as mandatory inputs. Since Nepal is
divided into seven MIP regions, the value for a MIP
region can have an integer ranging from 1 to 7 only.
In the example presented in Figure 1.10, the MIP
region can have values from 1 to 7. In case the user
enters different values (for example 8 as presented in
the figure), the program generates an error
prompting for the correct input of 1 to 7. The proper
value between 1 and 7 can be entered after clicking
Retry button.
Page: 9
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Page: 10
SHPP/GTZ
Wall Geometry
Top =501.91
HFL =501.41
2. Bottom Intake.
3. Settling Basin.
4. Anchor Block.
Crest =500.66
HFL =500.49
NWL =500.56
NWL =500.45
Orif ic
=0.2x0.32
Canal =500
Page: 11
SHPP/GTZ
2 DISCHARGE MEASUREMENT
2.1 GENERAL
Almost all potential hydropower project sites in Nepal are located in remote areas where there is a
complete lack of hydrological information. For micro-hydropower projects in Nepal, MGSP guidelines
requires at least one set of discharge measurement at the proposed intake site to be carried out in
the dry season, between November and May. Regular (such as monthly measurements)
measurements during dry seasons are recommended for mini and small hydropower projects.
Bucket method for flow up to 10 l/s, weir method for a flow from 10 to 30 l/s and for flows larger than
30 l/s salt dilution method (conductivity meter method) are recommended by MGSP. This chapter
deals with spreadsheet calculations based on the salt dilution method.
Since the salt dilution method is quick (generally less than 10minutes per set of measurement),
easier to accomplish and reliable, its accuracy level is relatively higher (less than 7%) than other
methods. This is suitable for smaller fast flowing streams (up to 2000 l/s), easier for carrying the
instrument in remote places. Consultants have been using mainly this method even though AEPC
and other guidelines have proposed different methods for different flows at the river. In this method,
the change of conductivity levels of the stream due to pouring of known quantity of predefined diluted
salt (50-300gm per 100 l/s) are measured with a standardized conductivity meter (with known salt
constant, k) at a regular interval (e.g., 5 seconds). For more information, please refer to MGSP Flow
Verification Guidelines or Micro Hydro Design Manual (A Harvey) or other standard textbooks.
Input parameters
River
Conductivity Meter
Date
Type of Salt
Conductivity Constant (m Siemens)
Water temp
Time Intervals (dt)
Weights of salt for sets 1 to 4 (M in g)
Readings (m & mbaseline) for sets 1 to 4
Table 2.2: First set conductivity reading for Salt Dilution Method (Example)
Water
Conductivity in
mS
5
25
34
32
30
28
26
10
26
35
32
29
28
26
15
27
35
32
29
27
26
20
28
35
31
29
27
26
25
29
35
31
29
27
26
Time(sec)
30
35
30
31
34
34
31
31
29
29
27
27
26
26
40
32
34
31
28
26
25
45
32
33
31
28
26
25
50
55
60
33
34
34
33
33
32
30
30
30
28
28
28
26
26
26
25
Total (mS) = Sm
Total readings (nr)
Sum
361
407
372
344
321
257
2062
70
Page: 12
SHPP/GTZ
Reading 1
Reading 2
Reading 3
Reading 4
25
24
24
26
24
25
10
27
24
25
15
28
24
26
..
..
With these input parameters, discharge at the stream can be calculated by the following procedures:
Stream Flow,
Q = M x k/A
Where,
Q = flow in litre/sec
M = mass of dry salt in mg (i.e.10-6 kg)
k = salt constant in (mS)/(mg/litre)
A = effective area under the graph of conductivity versus time, after excluding
the area due to base conductivity. The units for the area under the graph
is sec x mS. The area is determined as follows:
Area (A) = (Sm nr x mbaseline) * dt
Weighted averages of the individual flows thus calculated are computed. A typical spreadsheet is
presented in Figure 2.1. The average estimated discharge will further be used by Medium Irrigation
Project Method (MIP) to calculate long term average monthly flows. The calculation procedures for
the first set of measurement (Set 1) are:
Area (A)
= (Sm nr x mbaseline) * dt
= (2062-70*25)*5
= 1560 sec x mS
Discharge (Q)
= M x k/A
= 400000*1.8/1560
= 461.54 l/s
= 461 l/s
Page: 13
SHPP/GTZ
Referances: 6,12,13,15,16
Date
24-May-2006
Revision
2006.05
Project
Developer
Consultant
Designed
Checked
Meter
Salt
Given k
11 deg C
5 sec
1.8000
1580 gm
1795 gm
91
106
24
24
3433
3997
6245
7265
455 l/s
445 l/s
Average Discharge
400 gm
70
25
2062
1560
462 l/s
454 l/s
Conductivity mS
60
50
40
30
20
10
0
450
500
550
600
Time(sSalt
ec) =400gm, ASalt
eff =1560
=1580gm, ASalt
effSalt
=6245
=1795gm,
effeff
=7265
=0gmA
,A
=0
Date= 2006/5/24, 11deg C, HANNA Instruments (HI 933000), Iyoo Noon, k=1.8, Ave. Discharge = 453.89 l/s
Page: 14
SHPP/GTZ
3 HYDROLOGY
3.1 GENERAL
Hydrology is the science that deals with space-time characteristics of the quantity and quality of the
waters of the earth. It is the intricate relationship of water, earth and atmosphere.
Tools developed for estimating hydrological parameters for un-gauged catchment areas are mainly
based on regional correlations. The outputs of these tools are quite comparable to the actual
hydrological parameters for rivers having bigger catchment areas (100km2 or more).
Almost all potential micro and mini hydropower scheme
sites in Nepal have relatively small catchment areas and are
located in remote areas where there is a complete lack
small of hydrological information. It is recommended that at
least one set of actual measurement in dry season
(November-May) for estimating reasonably reliable long
term mean monthly flows. Long term mean monthly flows
are estimated by the use of a regional regression methods
called Medium Irrigation Project (MIP) method developed by
M. Mac Donald in 1990. For hydropower schemes having a
design discharge more than 100 l/s, flood hazards are
generally critical and flood flows should be calculated. Long
term mean monthly flows based on MIP method and flood
flows based on methodologies for estimating hydrologic
characteristics of engaged locations in Nepal, WECS/DHM
1990 Study (Hydest) are incorporated in Hydrology
spreadsheet. Brief introduction of these two methods are
presented in the subsequent sub-sections. It is worth noting
that MIP and HYDEST are only applicable for Nepal.
Atmosphere
Atmosphere
Hydrology
Water
Water
Earth
Earth
Topographic
Topographic Maps
Maps
Groundwater
Groundwater Data
Data
Evaporation
Evaporation and
and Transpiration
Transpiration Data
Data
MHP
MHP
Hydrological
Hydrological Data
Data
Soil
Soil Maps
Maps
Geologic
Geologic Maps
Maps
Hydrological
Hydrological Data
Data
Figure 3.2: Hydrological Data and MHP
Page: 15
SHPP/GTZ
1
2.40
1.80
1.30
1.00
2.60
6.00
14.50
25.00
16.50
8.00
4.10
3.10
2
2.24
1.70
1.33
1.00
1.21
7.27
18.18
27.27
20.91
9.09
3.94
3.03
3
2.71
1.88
1.38
1.00
1.88
3.13
13.54
25.00
20.83
10.42
5.00
3.75
Regions
4
2.59
1.88
1.38
1.00
2.19
3.75
6.89
27.27
20.91
6.89
5.00
3.44
5
2.42
1.82
1.36
1.00
0.91
2.73
11.21
13.94
10.00
6.52
4.55
3.33
6
2.03
1.62
1.27
1.00
2.57
6.08
24.32
33.78
27.03
6.08
3.38
2.57
7
3.30
2.20
1.40
1.00
3.50
6.00
14.00
35.00
24.00
12.00
7.50
5.00
Figure 3.4 represents a flow chart of the MIP model for calculating mean monthly flows based on a
set of low flow measurement. As shown in the figure, this model takes low flow measurement, its
date and MIP region number as inputs and processes them for estimating mean monthly flows for
that point on the catchment area. As stated earlier, the actual measurement date plays an important
role in computing more realistic mean monthly flows. This critical factor is often ignored by microhydropower Consultants resulting in highly unlikely flow estimation.
Page: 16
SHPP/GTZ
INPUT
INPUT
Low
Low flow
flow measurement
measurement
OUTPUT
OUTPUT
MIP
MIP
Measurement
Measurement date
date
MIP
MIP region
region number
number
Mean
Mean monthly
monthly flows
flows
2
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1
60, 1.88
45, 1.44
0, 1.38
15, 1.19
30, 1
0
March 15
April 15 Q corr
15
April 1
45.38
Days
If measured on
Q calculated
30
45
April 15
54.00
April 30
37.50
60
May 15
1
3
65
1.173
15%
Page: 17
SHPP/GTZ
Figure 3.6 is the graphical representation of the outcome of the MIP method. Interpolated MIP flows
corresponding to the measurement dates of April 1, 15 and 30 are presented. The design flow
exceeds 11 months and fulfills AEPC criteria if it is measured on April 15th. However, the design flow
exceeds only 10 months and does not meet AEPC criteria if it is measured on either 1st or 30th of
April.
E rro rs G e ne rate d b y u sin g mid mo nthly flow s
30
1 -A pr
25
1 5 -A p r
Discharge (m 3/s)
3 0 -A p r
Q dive rted
20
15
10
0
1
10
11
12
M ONTH
Page: 18
SHPP/GTZ
Flood peak discharge, QF, for any other return periods can be calculated using:
QF = e
(lnQ
2 + Ss
lnQF
Where, S is the standard normal variant for the chosen return period, from Table 3.2, and
slnQF =
Q100
Q2
ln
2.326
As shown in Figure 3.7, the Hydest method requires different catchment areas and monsoon
wetness index as inputs to estimate hydrological parameters such as the mean monthly flows,
floods, low flows and flow duration curve.
OUTPUT
INPUT
Total
Total catchment
catchment area
area (MMF
(MMF && FDC)
FDC)
Area
Area below
below 5000m
5000m (LF)
(LF)
Area
Area below 3000m
3000m (FF)
(FF)
*Monsoon
*Monsoon wetness
wetness index
index (MMF
(MMF && FDC)
FDC)
Monsoon
Monsoon wetness
wetness index=(Jun-Sept)
index=(Jun-Sept) mm
mm
Hydest
*Mean monthly
monthly flows
flows
Flood
Flood flows (2-100
(2-100 yrs)
yrs)
Low
Low flows(1,7,30
flows(1,7,30 && monthly)
monthly)
Flow
Flow duration (0-100%)
(0-100%)
** Area
Area =>100km
=>100km22
Discharge (l/s)
Bucket collection
<10
Weir
10-30
Salt dilution
>30
3. Since MIP method utilizes actual measured flow data, mean monthly flows should be
computed by using this method. Alternatively, HYDEST method may be used for catchment
area equal to or more than 100 km2.
4. The design flow for AEPC subsidized micro hydropower projects should be available at least
11 months in a year (i.e., the probability of exceedance should be 11 months or more). The
Page: 19
SHPP/GTZ
design flow corresponding to the installed capacity (Qd) should not be more than 85% of the
11-month exceedance flow. Loses and environmental releases should also be considered if
it exceeds 15% of the 11-month exceedance. There is a provision of 10% tolerance on Qd
at the time of commissioning a scheme.
5. The design flow for other projects should be based on the prudent practices of the
stakeholders and project optimization. For example for a small hydropower project with an
installed capacity of more than 1MW, the design flows should not exceed 65% probability of
exceedance. For projects less than or equal to 1MW, the design flows are estimated by
optimizing project installed capacities.
6. Construction of flood wall against annual flood is recommended if the design flow exceeds
100 l/s.
No
Is
A 3000
Given?
Q measured,
date measured,
MIP region from
the attached map
MIP
Q monthly
Q designed
& MGSP
Q diverted
Q losses
Q release
Q available
Q exceedance
Monthly
Hydrograph Q
Yes
Hydest
Flood flows
A 3000
End
th
Since the measured date of March 23 lies in between March 15 and April 15 ,
K March
= 1.38
K April
= 1.00
Kc March
Q March
Page: 20
SHPP/GTZ
Q April
Q May
Other mean monthly discharges are calculated similar to the discharge calculation for the month of
May.
Q2 inst
= 1.8767 x (A3000)
Q100 daily
0.7343
0.9527
0.8783
0.8448
= 0.8154 * (1.5+1)
0.9527
0.8783
= 1.8767 x (1.5+1)
0.8448
= 14.630 x (1.5+1)
= 1.952 m /s
3
= 4.197 m /s
3
= 8.987 m /s
3
= 28.669 m /s
Peak discharges for other return periods are calculated by using these formulas:
s l nQF =
Q100
Q2
ln
QF = e
(lnQ
2 + Ss
lnQF
2.326
3
= 85% of the 11 month flow exceedance from the MIP flow if the designed flow is
higher or the design flow.
= 73.389 l/s (since the design flow is higher and has 10 months exceedance only)
Qdiverted
Qlosses
Qrelease
Qrequired at river
A hydrograph including the design flow, exceedance of the proposed design flow and the flow
acceptable for AEPC is presented in Figure 3.9.
Page: 21
SHPP/GTZ
Referances:2,2,4, 6,12,13,15,16
Date
Revision
Project:
Developer
Consultant
Designed
Checked
24-May-2006
2006.05
INPUT
River name :
Location :
Measured flow for MIP method l/s:
Month and day of flow measurement:
MIP region (1 -7) :
Area of basin below 3000m elevation A3000 km2 :
Turbine discharge Qd l/s:
Water losses due to evaporation/flushing/seepage % of Qd :
Downstream water release due to environmental reasons % of Q lowest :
Chhyota Khola
Barand, Sertung VDC 2, Dhading
80
March
23
3
1.5
80
5%
10%
OUTPUT
MIP monthly average discharge
Month
@ river
To plant
January
169.55
77.25
February
117.62
77.25
March
86.34
77.25
April
62.57
56.31
May
117.62
77.25
June
195.83
77.25
July
847.13
77.25
August
1564.13
77.25
September
1303.23
77.25
October
651.93
77.25
November
312.83
77.25
December
Annual av
Q exceedence (month)
Q turbine for 11m
234.62
471.950
2
20
100
Discharges (l/s)
Qturbine (Qd)
Q diverted Qd+Qlosses
Q losses 5% of Qd
Q release 10% of Qlow
Q min required @ river
77.25
75.506
11
Long TermAverage Annual Hydrograph of Chhyota Khola river, Chhyota Khola MHP
1800
1600
MIPFlows
Q design =80 l/s with 10-month exceedence
1400
Discharge (l/s)
1200
1000
800
600
400
200
0
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Months
SHPP/GTZ
4 HEADWORKS
4.1
Headworks
A headworks consists of all structural components required for safe withdrawal of desired water from
a source river into a canal/conduit. Intake, weir, protection works, etc., are the main structural
components. Indicators of an ideal headworks can be summarized as:
1. Withdrawal of desired flows (i.e., Qdiverted and spilling in case of flood).
2. Sediment bypass of diversion structure (Continued sediment transportation along the river).
3. Debris bypass (Continued debris bypass without any accumulation).
4. Hazard flood bypass with minimum detrimental effects.
5. Sediment control at intake by blocking/reducing sediment intake into the system.
6. Settling basin control (settling and flushing of finer sediments entered into the system through
intakes or open canals).
Intake
An intake can be defined as a structure that diverts water from river or other water course to a
conveyance system downstream of the intake. Side intake and bottom intake are the common types
of river intakes that are used in Nepali hydropower schemes.
Conveyance Intake is an intake which supplies water to a conveyance other than the pressure
conduit to the turbine. Power Intake is an intake which supplies water to the pressure conduit to the
turbine.
Side Intake
A structure built along a river bank and in front of a canal / conduit end for diverting the required
water safely is known as a side intake. Side intakes are simple, less expensive, easy to build and
maintain.
Bottom/Drop/Tyrolean/Trench Intake
A structure built across and beneath a river for capturing water from the bed of a river and drops it
directly in to a headrace is known as a bottom intake. They are mainly useful for areas having less
sediment movement, steeper gradient, and surplus flow for continual flushing. Inaccessibility of
trashrack throughout the monsoon season and exposure of the system to all the bed load even
though only a small part of the water is drawn are the common drawbacks of drop intakes.
Weir
A weir is a structure built across a river to raise the river water and store it for diverting a required
flow towards the intake.
Protection Works
Protection works are the river protection and river training works to safeguard the headworks against
floods, debris and sediments.
Trashrack
A trashrack is a structure placed at an intake mouth to prevent floating logs and boulders entering
into headrace. Coarse trashracks and fine trashracks are provided at the river intake and penstock
intake respectively.
Page: 23
4.2
SHPP/GTZ
GENERAL RECOMMENDATIONS
General recommendations and requirements for headworks components such as weirs, intakes and
trashracks are briefly outlines in this section.
4.2.1
Weir
Type: A weir can be either temporary or permanent in nature. A dry stone or gabion or mud
stone masonry can be termed as a temporary weir whereas a cement masonry or concrete
weir can be termed as a permanent weir.
Location: It is recommended that the weir should be 5m to 20m d/s of side intake. This will
assure that water is always available and there is no sediment deposition in front of the
intake. A narrow river width with boulders is preferable for weir location.
Height: The weir should be sufficiently high to create enough submergence and driving head.
Stability: Permanent weir should be stable against sinking, overturning and sliding even
during the designed floods.
4.2.2
Intake
Type: Side intakes are suitable for all types of river categories whereas the drop intake is
recommended for rivers having longitudinal slopes more than 10% with relatively less
sediment and excess flushing discharge. The side intake is generally is of rectangular orifice
type with a minimum submergence of 50mm. The side intake should be at:
o
Alternatively, on the outer side of the bend to minimize sediment problems and
maximise the assured supply of water.
By the side of rock outcrops or large boulders for stability and strength.
Capacity: According to the flushing requirement and tentative losses the intake has to be
oversized to allocate an excess flow of 10% to 20% (or Qdiverted).
A coarse trashrack should be provided to prevent big boulders and floating logs from
entering into the headrace system.
A gate/stop log should be provided to regulate flow (adjust/ close) during operation and
maintenance.
To optimize downstream canal and other structures, a spillway should be provided close to
the intake.
4.2.3
Intake Trashrack
The recommended intake coarse trashrack is made of vertical mild steel strips of 5mm*40mm to
5mm*75mm with a clear spacing not exceeding 75mm. The approach velocity should be less than
1.0m/s. For transportation by porters in remote areas, the weight of a piece of trashrack should not
exceed 60 kg. Placing of trashrack at 3V:1H is considered to be the optimum option considering the
combined effect of racking and hydraulic purposes.
4.3
There are two spreadsheets for designing intake structures, They are sideIntake and
BottomIntake for designing side and bottom intakes respectively. The first part of the side intake
calculates trashrack parameters while the second part of it calculates side intake parameters
including spillways for load rejection and flood discharge off-take. The second spreadsheet
calculates all the design parameters for a drop intake.
Page: 24
SHPP/GTZ
Since most of the program flow chart in this section is self explanatory, only critical points are
explained.
Figures 4.1 to 4.7 present the assumptions, flow charts and typical examples for calculating
trashrack parameters, side intake and drop intake dimensioning.
K = (hf + hb)/(Vo^2/2g)
Is
Yes
cleaning
K1=0.3
manual
No
K1
K1=0.8
MHP = 0.55
B = S/(h/sinf)
End
Page: 25
SHPP/GTZ
The trashrack surface area coefficient K1 for automatic raking is 0.8 whereas it is 0.3 for manual
raking suggesting that the raking area for manual operation to recommended surface area is 3.33
times more than the theoretical area. Manual racking is recommended for Nepali micro and mini
hydropower. Since the consequence of temporary reduced trashrack area in micro and mini hydro is
not severe and the trashrack sites are generally accessible to operators all the year, the average of
automatic and manual racking coefficient of 0.55 (i.e., 80% more than the theoretical area) is
recommended for practical and economic reason.
Flood
ht
(4/3)
h friction
= kt * (t/b)
h bend
h total
A surface S
Width B
Normal condition:
Depth @ canal (hc) = h submergence + height of orifice + height of orifice sill from bottom of the canal
= 0.05+0.2+0.2 = 0.45m
2
= (Vo/c) /2/g
Page: 26
Start
Orifice
V coeff c, Vo, n,
d/s submergence hsub,
H from canal bed h bot,
height H
SHPP/GTZ
hc=hsub+H+hbot
dh = (Vo/c)^2 / 2g
hr = hc + dh
hw = hr+0.1
End
River
Crest length L
Qf flood
Yes
Is
W c=W c
W c provided?
No
W c=2*hc
ycf = (Qf^2/L^2/g)^(1/3)
hrf = hw+yc
Flood:
2 2
1/3
2 2
1/3
Critical depth at crest (yc) = (Qf /L /g) = (10 /5 /9.81) = 0.742 m
Head at river (hf r)
Water depth at canal during flood is calculated by equating and iterating flow coming from orifice to that
of canal flow. Since this iterative process is tedious and erroneous, most of the micro-hydropower
consultants do not calculate it precisely. This iterative process is introduced in the presented
spreadsheet. In case this cell generates VALUE# error, select the cell, press F2 and press Enter. The
final canal depth is
(hcf)
= 0.490m
Q intake (Qf)
= 0.218 m /s
1.5
= 0.218/1.6/(2*0.125)
1.5
= 0.218/1.6/(0.125)
= 1.525 m
= 3.078 m
Care should be taken while designing spillway lengths. Ls for Gfm (d/s Obs & 100% hot -50) is only
applicable when full downstream obstruction for flood off-take is provided with the help of stop logs or
gates. Otherwise, the gradually varying water profile at the spillway has to be considered.
Page: 27
SHPP/GTZ
24-May-2006
2006.05
Referances: 6,12,13,15,16
Date
Revision
Project
Developer
Consultant
Designed
Checked
Design
Flood Level
Coarse Trashrack
Min 100 thick & 1000 wide
walkway Rcc slab
Orifice (H*B)
Top =501.91
Normal
1
river level 3
.
Weir Crest
hbot
h r-hc
HFL =501.41
hc
Canal
LS
Fb
.
H
River bed
h cf
h sub
hr
h rf
Crest =500.66
Compacted earth/200mm
stone soling
HFL =500.49
NWL =500.56
NWL =500.45
Orific
=0.2x0.32
Canal =500
Trashrack calculations
Input
Output
Trashrack coeffieient kt 2.4 2.4
Bar thickness t mm
4.00
Clear spacing of bars b mm
25.00
Approach velocity Vo m/s
0.50
Angle of inclination from horizontal f deg
60.00
Flow deviation b deg
20.00
Design Discharge Qd cumec
0.077
Height of trashrack bottom from river bed ht
0.200
Canal invert level (m)
500.00
0.0023
0.0044
0.5226
0.0067
0.3750
0.3647
0.8906
River
Velocity coeff of orifice c 0.8
Crest length L m
5.000
0.8
Velocity through orifice Vo m/s
1.2
Provided Q flood m3/s
10.000
Manning's coeff of roughness 0.02
Q flood m3/s (Q20 for MHP with Qd>100)
16.334
0.02
Downstream submergence depth hsub m
0.050
Used Q flood
10.000
Orifice height H m
0.200 Canal & Spillway
Height of orifice from canal bed h bot m
0.200
Spillway crest height above NWL m
0.050
Provided water depth in the river hr (m)
Spillway discharge coeff 1.6
1.6
Provided canal width (m)
0.500
Provided Freeboard h fb1 m
0.300
Output
Normal Condition
Canal witdth d/s of orifice
1/Slope of canal immediately d/s of orifice
Depth of water in canal hc m
Free board in canal h fb m
Area of orifice A m2
Width of orifice B m
Actual velocity through orifice Vo act m/s
Canal width Wc m
Water level difference dh m
Water depth in the river hr = hc + dh m
Height of weir (hw = hr+0.1) m
Spillway overtopping height h overtop m
Flood
0.500
Critical depth of water at crest yc m
1865
Flood head at river hf r = hw+yc m
0.450
Head difference dhf
0.300
Velocity through orifice Vof m/s
0.064
Q intake Qf cumec
0.321
Depth of water at canal (hc f) m
1.200
0.500 Spillway
0.115
Ls for Qf m (d/s Obs & 100% hot -50)
0.565
Length of spillway Ls1 for Qf m (d/s Obs)
0.665
Length of spillway Ls2 for Qf-Qd m
0.125
Designed spillway length Ls m
0.742
1.406
0.916
3.392
0.218
0.490
1.521
3.078
3.978
3.978
4.2.5
SHPP/GTZ
The example presented in Figure 4.7 follows the procedures presented in Figure 4.6. This example
is taken from a 4500kW Sarbari Small Hydropower Project, Kullu, India. Although the calculation
procedures for the drop intake are relatively straightforward and simple, it has more restrictions and
limitations regarding the stream geometry and operational conditions.
Based on the flow conditions and the slope of rack, flow immediately upstream of the rack may be
either critical or sub-critical. Critical depth at the entrance of the rack has to be considered if the rack
is steeper (more than 15o). For more details, please refer to EWI UNIDO Standard.
The main differences between considering critical flow and normal flow conditions are presented in
the Table 4.1. In the presented spreadsheet, critical depth of upstream flow of the intake is
calculated and presented if normal flow (sub-critical) is considered.
Start
River
River W idth (Br)
Head of u/s water (ho)
U/s water velocity (vo)
River gradient (i) degrees
hof, vof
Trashrack
Aspect ratio (L across river/B along river)
Design Discharge (Q)
Gradient (b) deg, Contraction coeff (m)
Witdth/diameter (t), Clearance (a)
d = t + a, he = ho = vo^2/2g
X = =0.00008*b^2 - 0.0097*b + 0.9992
c =0.6*a/d*(COSb)^1.5
Yc Considered?
Yes
No
h =2/3*c*he
Qo u/s = Br * ho * vo
Qof u/s = Br * hof * vof
End
h = *Yc
Qo u/s = v (9.81 * ho 3 * Br 2 )
Qof u/s = v (9.81 * hof 3 * Br 2 )
L =SQRT(3*Q/(2*c*m*L/B ratio*SQRT(2*9.81*h)))
L' = 120% of L, b = L/B ratio * L, A=L'*b
Qu u/s = Qo u/s Qdesign
h f = 2/3*c*(ho + vo f^2/2g)
Q in f= 2/3*c*m*b*L'*SQRT(2*9.81*h f)
Quf d/s = Qof u/s of intake -Q in f
The calculations presented in Figure 4.7 are verified in the following section. In this example the flow
upstream of the intake is considered to be of critical.
Normal condition:
c/c distance of trashrack bars d (mm) = t + a = 60+30 = 90mm
Kappa (c)
= * of Yc = * 0.226
= 0.170 m
SHPP/GTZ
= SQRT(3*Q/(2*c*m*L/B ratio*SQRT(2*9.81*h)))
= SQRT(3*2.7/(2*c*0.85*3.546468*SQRT(2*9.81*.170)))
= 2.249 m
Length (L) m
= L * b = 2.249 * 7.975
2
= 17.935 m
= Qo u/s Qd = 2.7-2.7
3
= 0 m /s
Qo in (off-take) (m /s)
Page: 30
SHPP/GTZ
24-May-2006
2006.05
Sarbari SHP
Kullu, Himanchal Pradesh, India
Referances: 6,7,8,12,13
Date
Revision
Project
Developer
Consultant
Designed
Checked
Pushpa Chitrakar
Weir Geometry
HFL =501.91
NWL =500.23
Top =500
Trashrack
Top =498.68
Width =1.82
Input
Output
c/c distance of trash rack bars d mm =
Total head (he) m =
kappa (c) =
velocity head (h) m =
Correction factor ( c) =
Length of intake (L) m =
Length (L' ) m =
Intake length across the river (b) m =
Area of intake (A=L' *b) m2 =
90
0.340
0.749
0.170
0.146
2.249
1.819
7.975
17.935
Page: 31
2.700
0.000
1.906
1.864
325.497
7.318
318.178
SHPP/GTZ
5 HEADRACE/TAILRACE
5.1
GENERAL
A headrace or a tailrace can be defined as a conveyance system that conveys designed discharge
from one point (e.g. intake) to another (e.g. forebay). Generally canal systems are used in all micro
hydropower schemes whereas pipe systems are used for specific e.g. difficult terrain. A canal can
be unlined (earthen) or lined (stone masonry or concrete). Rectangular and trapezoidal canal cross
sections are mostly used profiles. Pipes used in MHP can be of HDPE or mild steel and it can be
either open or buried.
Mild steel and glass reinforced pipe (GRP) headrace-cum-penstock pipes are getting popularity in
mini and small hydropower schemes in Nepal. Because of the easier sediment handling facility and
better financial parameters, a layout with headrace-cum-penstock pipe has been adopted in many
micro, mini and small hydropower projects in Nepal.
For computing head losses, Mannings equation is used for canal whereas Darcy-Weisbach equation
is used for pipe.
5.2
GENERAL RECOMMENDATIONS
General recommendations and requirements for designing canal and pipe headrace systems are
outlined here.
5.2.1
Canal
a) Capacity: The canal should be able to carry the design flow with adequate freeboard and
escapes to spill excess flow. A canal should generally be designed to carry 110 to 120 % of
the design discharge.
b) Velocity: Self cleaning but non erosive ( 0.3m/s).
c) Unlined canal: In stable ground for Q 30 l/s
d) Lined canal: For higher discharge and unstable ground. Canals with 1:4 stone masonry or
concrete are recommended. Care should be taken to minimize seepage loss and hence
minimize the subsequent landslides.
e) Sufficient spillways and escapes as required.
f)
g) Stability and Safety against rock fall, landslide & storm runoff. A catch drain running along
the conveyance canal is recommended for mini and small hydropower projects.
h) Optimum Canal Geometry: Rectangular or trapezoidal section for lined canal and trapezoidal
section for unlined canal are recommended. Unequal settlement of lined trapezoidal canal
should be prevented.
5.2.2
Pipe
Page: 32
SHPP/GTZ
5.3
5.3.1
Canal
Canal
Calculations for a rectangular stone masonry headrace canal for 185 l/s flow presented in Figure 5.2
(Intake Canal in second column) are briefly described in the following section. This example is taken
from a 750kW Sisne Small Hydropower Project, Palpa, Nepal.
Present Canal:
Area A m
= B+2*H*N
2/3
0.5
= 0.5+2*0.3*0 = 0.5m
2/3
0.5
Velocity V m/s
Headloss hl (m)
Page: 33
SHPP/GTZ
Depth Do (m)
Headloss hl (m)
Critical dia of sediment d crit (mm) = 11000*r*S = 11000*0.136*0.0050 = 8.271mm (i.e., the canal
can tranport (self clean) sediments of diameter 8.271mm or less during its
normal operation)
Start
Project name, Reach name,
Design discharge (Qd)
Roughness coefficient (n)
Side slope (N)
Sectional profile
Canal length (L)
1/canal slope (1/S)
Canal depth/diameter (D)
Freeboard (FB)
Canal width (B)
Desired velocity (Vo)
Canal drop di (V) & hi(H)
r = A/P, Qc = A*r^(2/3)*S^0.5/n
FB=min(0.3,0.5*D)
V = Q/A, hl =S*L+di
hl =hl previous + hl (continuous)
d crit =11000*r*S
Semicircular = 0.4*SQRT(A)
Trapezoidal=0.5*SQRT(Sin(N)*A/(2-COS(N))
Rectangular/Traingular = 0.35*SQRT(A)))
Ho = Do + FBo
Channel width Bo
Semicircular = 2*Do
Rectangular = 4*ro
Traingular = 5.7*ro
Trapezoidal = 4*ro/Sin(N)
hl =S*L+di
Hl =hl previous + hl
d crit =11000*r*S
End
Page: 34
SHPP/GTZ
Referances: 6,12,13,15,16
Date
24-May-2006
Revision
2006.05
Project
Developer
Consultant
Designed
Checked
Input
Type and Name
Flow (m3/s)
Roughness coefficient (n)
Sectional Profile
Side slope N (1V:NHorizontal)
Trapezoidal
0.5
0.5
Main3
0.145
0.145
0.02
0.02
Semicircular
00
Triangular
0.5
0.5
20
40
150
120
77
200
30
72
0.300
0.525
0.300
0.300
Freeboard FB (m)
0.300
0.250
0.150
0.150
0.500
1.000
0.400
0.400
1.000
1.500
1.500
1.500
0.01299
0.00500
0.03333
0.01389
Channel Drops di m
Channel Drops Horizontal length hi m
Desired velocity Vo (m/s)
Output
Side slope d (degrees)
Canal slope S
Total depth H (m)
63.435
63.435
0.600
0.775
0.450
0.450
20.000
60.000
210.000
330.000
Area A m2
0.150
0.663
0.035
0.060
0.500
1.525
0.400
0.400
1.100
2.174
0.471
0.671
Chainage L (m)
Present canal
0.136
0.305
0.075
0.089
0.226 high
1.249 high
0.057 low
0.071 low
ok
low
ok
ok
1.233
0.219
4.103
2.417
1.72 Ok
2.06 Ok
0.93 Not Ok
1.21 Not Ok
0.260
0.200
5.000
1.667
0.260
19.481
0.460
16.769
5.460
27.500
7.126
13.665
0.1850
0.6022
1.74 Ok
0.1505
0.301
0.150
0.451
0.602
0.0050
0.100
0.100
8.271
0.0967
0.7636
1.11 Not Ok
0.1180
0.236
0.263
0.498
0.528
0.0112
0.449
0.549
14.584
0.0967
0.9949
0.98 Not Ok
0.1244
0.497
0.150
0.647
0.995
0.0145
2.175
2.724
19.834
0.0967
0.4867
1.4 Not Ok
0.1088
0.218
0.150
0.368
0.487
0.0173
2.079
4.803
20.736
Optimum canal
Area Ao m2
Top Width T (m)
Critical Velocity Vc m/s & Remarks
Hydraulic Radius ro (m)
Channel Depth/diameter Do (m)
Freeboard Fbo (m)
Total depth Ho (m)
Channel Width Bo (m)
Canal Slope
Headloss hlo (m)
Total headloss Hlo(m)
Critical dia of sediment d crito (mm)
SHPP/GTZ
Pipe
Calculations for a headrace pipe presented in Figure 5.5 are briefly described in the following
section. The trashrack calculations are similar to the trashrack calculations presented earlier in the
intake design, hence it is not presented in this section. Trashrack loss of 0.02m is taken in this
example. In this example, one 140m long HDPE pipe with 260mm internal diameter is considered
for a design flow of 160 l/s each.
Sizing of headrace pipe
Headloss
HDPE pipe roughness, k =0.06 mm
k 0.06 mm
=
= 0.000231
d 260 mm
1.2Q 1.2 x0.160
=
= 0.73846
d
0.260
From Moody chart (Appendix), f=0.0153. Based on an iterative method presented in Laymans
Guidebook on How to Develop a Small Hydro Site, European Small Hydropower Association (ESHA),
the presented spreadsheet calculates this friction factor and greatly speeds up the pipe selection
decision for consultants by iterating following equations:
Friction loss
= f
l V2
l
= 0.0826 * Q 2 * f 5
d 2g
d
140
= 3.82 m
0.265
Turbulent losses considering, K entrance for inward projecting pipe= 0.8, Kexit=1.0 and Kbends based
on the bending angles (see Table in the Appendix)
V 2
\ hturbulentlosses = (K entrance + K bends + K valve + K others + K exit )
2g
3.012
= (0.8 + 0.57 + 0 + 0 + 1) *
= 1.10m
2 x 9.81
Total head loss= 3.82 m + 0.02+1.10 m = 4.94 m
Page: 36
SHPP/GTZ
Water level difference between intake and storage reservoir is 7m and 95% of this head is
allowed for total headloss. Only 70.56% is estimated as the total headloss. Although the
exiting water has some residual head, it is recommended to provide some marginal residual
head for safety. The HDPE pipe does not need expansion joints and therefore not
calculated.
Start
Project
Name,
Location,
Life
Hydraulics
Qd, Hg, RL us,
%hl, Entrance,
Exit, R/d
Pipe
#, Material, Fabrication
If steel, Laying, Valve,
t, L, q(upto 10)
Exp Joint
Dimensions, Position
during installation
Hydraulics
hl(friction, turbulent)
Other criteria checking
Trashrack
Bar type,
t,b, Vo,
F, b,H
Exp Joint
Tmax, Tinst,
Tmin, Group
L (5)
Trashrack
hl, Surface Area,
Width, h submerge
End
Figure 5.4: Flow chart for pipe design
Page: 37
SHPP/GTZ
Date
24-May-2006
Revision
2006.05
Project:
MHP in Jumla
Developer
Consultant
Designed
Checked
Location:
Jogmai
Pushpa Chitrakar
INPUT
Hydraulics:
Diversion flow Qd (m3/s)
Flow in each pipe Qi (m3/s)
Gross headHg (m)
15
0.160
1950.00
0.160
95.00%
7.000
Headrace pipe
HDPE
Exit (Yes/No)
Yes
NA
NA
No of pipes
Bending angle 01
1.00
20.00
NA
Burried
Bending angle 02
Bending angle 03
Bending angle 04
Bending angle 05
4.00
6.00
20.00
282
260
NA
Bending angle 06
Bending angle 07
Bending angle 08
3.0
Bending angle 09
140.000
Bending angle 10
Pipe Material
Welded / Flat rolled if steel
Rolled if steel
Type if steel
Burried or exposed
Type of valve
Non standard ultimate tensile strength (UTS) N/mm2
Estimated pipe diameter d(mm)
Provided pipe diameter d(mm)
Min pipe thickness t (mm)
Provided pipe thickness t (mm)
Pipe Length L (m)
Trashrack
t
6.00
b
20.00
Vo
1.00
f
60.00
Q
0.160
H
3.00
Tmax (deg)
T installation
Tmin
40
20
50.00
100.00
150.00
200.00
250.00
hf
0.0213
hb
H coeff
0.4174
H
0.0213
S
0.8006
B
0.23
k
2.40
Flat
Expansion Joints
OUTPUT
Trashrack
Min Submergence
1.39
0.80
K bend 05
K bend 10
K bend 01
K bend 02
K bend 03
K bend 04
0.16
0.13
0.13
0.16
K bend 06
K bend 07
K bend 08
K bend 09
K valve
K exit
K others
K Total
CGL=1.5v^2/2g
0.69
1.00
2.37
Hydraulics
0.053
0.07
3.01
0.06
0.00023
687032
Turbulent
0.0153
1950.000
1943.000
OKAY
3.82
1.10
0.02
4.94
70.56% Ok
dL theoretical
dL recommended
dL for expansion
dL for contraction
Page: 38
SHPP/GTZ
SETTLING BASINS
Page: 39
SHPP/GTZ
Gravel Trap
General recommendations and requirements for designing a gravel trap are outlined in the following
sections:
1. Location: Close to intake and safe.
2. Dimensions: Sufficient to settle and flush gravel passing through upstream coarse trashrack.
3. Spilling: Sufficient spillway/vertical flushing pipe.
4. Spilling and flushing: back to the river.
5. Material: 1:4 cement stone masonry with 12mm thick 1:2 cement plastering on the waterside
or structural concrete.
6. Recommended settling diameter and trap efficiency are 2mm and 90% respectively.
Page: 40
SHPP/GTZ
7. Sediment storage zone: Adequate storage for 12 hours minimum (flushing interval).
8. Drawdown: Drawdown discharge capacity should be at least 150% of the design discharge.
9. Aspect ratio (straight length to width ratio): 1.5 to 2 for micro-hydropower gravel trap. The
recommended aspect ratio of mini and small hydropower gravel trap is 4.
6.3.2
Settling Basin
Mini/Small Hydro
0.3-0.5
90%
10m
10m
0.3
90%
10 to 100m
10 to 50m
0.2
90%
50 to 100m
0.2
95%
Forebay
Page: 41
SHPP/GTZ
d. Clearance: 0.5 * nozzle diameter in case of Pelton or half the distance between
runner blade in case of Crossflow/Francis.
e. Velocity: 0.6 to 1 m/s
f.
The spreadsheet is designed to cater for all types of settling basins and with all possible spilling and
flushing mechanisms. Some of the main features are listed below:
1. A single spreadsheet for:
a. Gravel Trap
b. Settling Basin (Desilting)
c. Forebay-cum-Settling Basin
2. Settling of sediment using:
a. Ideal settling equation
b. Vetters equation
3. Flushing of deposited sediment during:
a. Normal operational
b. Drawn-down condition
4. Sediment flushing with:
a. Vertical flushing pipe
b. Gate
c. Combination of both
5. Spilling of excess flow due to:
a. Incoming flood
b. Load rejection
6. Spilling of excess flow with
a. Spillway
b. Vertical flushing pipe
c. Combination of both
7. Drawdown / Dewatering with:
a. Vertical flushing pipe
b. Gate
8. Rating curve for the gate: According to Norwegian Rules and Regulations of Dam
Construction, a gate rating curve for the designed parameters is computed. According to this
manual, the flow through gate is of free flow type until the gate opening is two third of the
water depth behind the gate. Beyond this level (i.e., the gate opening higher than 2/3 of the
water depth behind the gate), the flow through gate is a pressure flow.
9. Multiple basins
10. Combination of approach canal / pipe options
Page: 42
SHPP/GTZ
Gate
Lifting force F(kg)=W buoyant + 1000*m*Asub*hcg
Page: 43
SHPP/GTZ
= 2.5m
Length of basin L
= Asi/B = 25/2.5
= 10m, which is 4 times the width hence, satisfies the requirement.
= h ot =(Q1/(1.9*PI()*n1*d1+Cd*Ls))^(2/3)
= (0.455/(1.9*pi()*1*.3+1.6*1))^(2/3)
= 0.262 m
Q pipe
Q spillway
3. Flushing of deposited sediment through the flushing pipe: The pipe diameter will be the biggest
of :
a. For incoming flow and draw down:
D1 = (Qflushing%*4*Qi/(PI()*Cd*SQRT(h NWL+h flush)))^0.5
Page: 44
SHPP/GTZ
= (100%*4*0.455/(pi()**2.76*SQRT(1.36+1.7)))^0.5
= 0.35m
b. For incoming flow only:
D2
=(4*Qi/(PI()*Cd*SQRT(hflush)))^0.5
= (4*0.455/(pi()**2.76*SQRT(1.7)))^0.5
= 0.4m
Date
24-May-2006
Revision
Project:
Location:
2006.05
Jogmai
Developer
Consultant
Designed
Checked
50.000
0.421
1.50
15.12
0.63
0.034
Canal
0.455
0.300
85%
15
0.037
2
8
24.000
0.241
2600
50.00
Pipe
1950.00
1.70
1.00
0.05
1.60
0.30
2.76
1.00
0.455
3.258
2.500
1.000
0.50
0.50
0.30
10.000
4.000
0.755
1.888
4.010
0.471
1.385
3.750
10.000
Spillway
Freeboard m
Spillway overtopping height h overtop m
Spillway length for Qf (flood and non operational)
Combination of vertical flushing pipe and spillway
Vertical flushing pipe diameter d1 m
No of vertical flushing pipe
Spillway length used (m)
Flood and Under Operation (Qf- Qd)
H overtopping
Discharge passing through vertical pipe
Discharge passing over spillway
0.300
0.125
0.30
1.00
1.00
6.43
6.43
3.18
1.00
0.262
0.240
0.215
Figure 6.4: Typical example of a settling basin (Settling basin, spilling and flushing).
Page: 45
SHPP/GTZ
In the second case, the depth of water during flushing (yfi) may be added to h flush for higher
precision. This is not considered here. The recommended minimum diameter of the flushing pipe
diameter is 0.4 m. Use of flushing pipe should be restricted to micro-hydropower projects. For
larger projects, use of gates is recommended.
The gate curve in the example presented in Figure 6.5 includes the gate dimensions, forces and
the rating curve. The rating curve of the gate versus different gate opening can be computed by
entering allowable gate opening at the lowest input cell and clicking Calculate Gate Rating Curve
button.
Gate
Opening
Hg
0.000
0.033
0.067
0.100
0.133
0.167
0.200
0.233
0.267
0.300
0.333
0.367
0.400
0.433
0.467
0.500
0.35
0.40
0.39
Gate
Buoyance weight of the gate W kgf
Gate Opening B, (m)
Gate Opening H (m)
Submerged area of th gate A m2
Water surface to cg of submerged area h m
Coeff of static friction mu
Lifting force F kgf
H. of water (H1)
300.00
1.00
0.50
0.50
1.11
0.90
799.50
1.36
Relative
Discharge
Gate Openinig One basin
Hg/H1
Q
0.000
0.000
0.025
0.127
0.049
0.249
0.074
0.366
0.098
0.479
0.123
0.591
0.147
0.700
0.172
0.807
0.196
0.912
0.221
1.016
0.245
1.117
0.270
1.216
0.294
1.312
0.319
1.406
0.343
1.497
0.368
1.586
Figure 6.5: Typical example of a settling basin (Gate and rating curve).
The last part the spreadsheet can be used if the considered basin is a settling basin cum forebay.
The basic penstock inlet geometry is computed in this section. An example is presented in Figure
6.6.
1.800
0.367
0.400
0.433
0.467
0.500
1.600
1.400
Av. H ot =0.125m
Water depth 0.76m
0.265
0.289
0.313
0.337
0.361
1.230
1.328
1.423
1.516
1.606
1.200
1.000
Penstock diameter m
Penstock velocity m/s
Submergence depth of penstock pipe m
Height of pipe above the base slab m
Min. pond depth m
Effective thickness of penstock mm
FS for air vent (5 burried, 10 exposed)
Young's modulus of elasticity E N/mm2
Penstock inlet gate (Yes/No)
Air vent diameter mm
0.800
0.600
0.400
0.200
Width 2.5m
0.000
half of Gr expansion
0.500
1.000
Width 2.5m
Flushing cone/spillway O
L =10
Spillway
0.500
0.300
Slope 1:50
Page: 46
0.41
3.45
0.91
0.30
1.62
3
10
200000
No
Nominal
SHPP/GTZ
GENERAL
A penstock pipe conveys water from free flow state (at a settling basin or a forebay) to pressure flow
state to the powerhouse and converts the potential energy of the flow at the settling basin or forebay
to kinetic energy at the turbine.
7.2
GENERAL RECOMMENDATIONS
1. Material: Mild steel (exposed and buried) and HDPE/GRP (buried) pipes should be used as
penstock pipes. For mild steel pipes, flanged connections are recommended for low head (up to
60m) micro-hydropower projects. In other cases, site welding is recommended. A combination
of HDPE/GRP and mild steel can also be used.
2. For exposed (i.e., above ground) mild steel penstock alignment, a minimum clearance of 300 mm
between the pipe and the ground should be provided for ease of maintenance and minimising
corrosion effects.
3. GRP/HDPE pipes should be buried to a minimum depth of 1 m. Similarly, if mild steel penstock
pipes have to be buried, a minimum of 1 m burial depth should be maintained and corrosion
protection measures such as high quality bituminous/epoxy paints should be applied. Due to
higher risks of leakage, flange connected penstocks are not recommended to be buried.
4. The recommended initial trial internal diameter (D) can be calculated as:
D = 41 x Q 0.38 mm
Where, Q = Design flow in l/s
5. Total penstock headloss should not be more than 10% of the penstock gross head.
6. Anchor / Thrust blocks at every horizontal and vertical bend are recommended. For micro
hydropower projects, these blocks are also recommended for every 30m of straight pipe stretch.
7. Expansion joints should be placed immediately downstream of every anchor block for exposed
mild steel penstock.
8. Instead of providing an expansion joint immediately upstream of turbine, a mechanical coupling is
recommended for ease of maintenance and reduced force transmitted to the turbine casing.
7.3
Page: 47
SHPP/GTZ
Start
Project
Name,
Location,
Life
Hydraulics
Qd, Hg, RL us,
%hl, Entrance,
Exit, R/d
Exp Joint
Dimensions, Position
during installation
Pipe
#, Material, Fabrication
If steel,Laying, Valve,
t, L, q(upto 10)
Power
Pturbine,P MGSP,
P hnetPCU M
Trashrack
Bar type,
t,b, Vo,
F, b,H
Hydraulics
hl(friction, turbulent)
Other criteria checking
Exp Joint
Tmax, Tinst,
Tmin, Group
L (5)
Trashrack
hl, Surface Area,
Width, h submerge
End
Figure 7.1: Flow diagram of penstock design
7.3.2 Typical example of a penstock pipe
Figure 7.1 presents calculation procedures applied in the example presented in Figures 7.2 and 7.3.
The presented example is taken from the 500kW Jhakre Mini Hydropower Project, Dolakha. For the
given head of 180m and discharge of 450 l/s, three units of two-nozzle Pelton turbines are selected.
Since trashrack and pipe hydraulics are similar to headrace pipe presented earlier, the detailed
calculations are not presented in this section. The steel pipe thickness, expansion joints and power
calculations are presented in this section. It is assumed that the valve closing is of slow type. The
minimum factor of safety for penstock is chosen to be 2.5.
Pipe thickness:
It is worth noting that in reality the diameter of penstock pipe is optimized by calculating marginal
costs and benefit method. In this method, the incremental benefit of annual energy by increasing the
pipe diameters and corresponding increase of costs are plotted. The intersecting point represents
the cost of optimum diameter. Alternatively, net present values of these cash/cost flow can be
calculated and the net present value (NPV) of marginal benefit from energy gain should be higher
than that of the marginal cost of that diameter.
Lets consider 4mm thick 300mm diameter pipe, the wave velocity
a=
1440
2.1 x10 9 x d
1 +
E xt
1440
2.1 x 10 9 x 0.300
1+
200 x 10 9 x 6
1000
= 1071.454 m / s
Page: 48
SHPP/GTZ
hsurge
= a * V/(g*njet) = 1071.454*2.83/(9.81*6)
= 51.484m
htotal
t effective
S .F . =
teffective x S
5 x htotal x 103 x d
= 2.79 which does not exceed the allowable FS of 2.5, hence OK. This factor of
safety should be used for thinner penstock.
Date
Revision
Project:
Jhankre mini-hydropower
Himal Power Limited
BPC Hydroconsult
Pushpa Chitrakar
Pushpa Chitrakar
Developer
Consultant
Designed
Checked
Location:
10-Nov-2005
2005.10
Barand, Sertung VDC 2, Dhading
INPUT
General:
Jogmai I
Project:
Location:
Ilam
Hydraulics:
Diversion flow Qd (m3/s)
Flow in each pipe Qi (m3/s)
Gross head (from forebay) Hg (m)
Power:
Turbine type (CROSSFLOW/PELTON)
No of total jets (nj)
10
0.450
0.450
180.00
1213.90
16.00%
79.38%
Pelton
6
Valves (Sperical/Gate/Butterfly)
Taper (Yes/No)
Butterfly 0.3
Yes
Exit (Yes/No)
No
30.00
3
Steel
Welded
Rolled
IS
Exposed
No
1.5
1.00
Bending angle 06
2.00
Bending angle 07
11.00
Bending angle 08
4.00
Bending angle 09
11.00
Bending angle 10
450 Pipe thickness t=>t min, t act (mm)
3.0
Roughness coefficient (ks)
418
550.000
b
20.00
Vo
1.00
f
71.56
Tmax (deg)
T installation
Tmin
40
20
10.00
15.00
b
0.00
Q
0.450
25.00
14.00
0.00
0.00
0.00
0.00
6.0
0.060
H
0.70
20.00
2.5
0.5
No
0.45
22
Sharp cornered
30.00
Page: 49
SHPP/GTZ
OUTPUT
Trashrack
hf
hb
H coeff
0.0233
0.0000
0.4572
0.0233
2.0555
2.79
K Total
K bend 01
K bend 02
K bend 03
K bend 04
Min Submergence
1.84
CGL=1.5v^2/2g
0.61
2.06
0.50
K bend 05
0.24
K bend 10
0.00
0.18
0.21
0.19
0.21
K bend 06
K bend 07
K bend 08
K bend 09
0.22
0.00
0.00
0.00
K valve
K taper
K exit
K others
0.30
0.00
0.00
0.00
Hydraulics
0.159
1213.90
0.11
2.83
0.060
1.333E-04
1116427
Turbulent
0.0138
1033.90
OKAY
6.87
0.84
0.02
7.73
4.3% Ok
200000
410
6.000
231.48
Diameter (mm)
450.000
t effective (mm)
3.55
172.268
4.71
1071.454
Comment on thickness
NA, No gate
Pipe Area A (m )
Hydraulic Radius R (m)
Velocity V (m/s)
Pipe Roughness ks (mm)
Relative Roughness ks/d
Reynolds Number Re = d V /Vk
Type of Flow
Friction Factor f
Factor of Safety
2
1.03 Ok
2.79
0.00000
51.484
308.907
550.000
Ok
67.45
258.42
206.94
Power
Turbine efficiency as per MGSP
Available shaft power(kW)
Reqd.'Turbine Capacity (+10%) (kW)
75.00%
570.36
627.39
397.31
456.29
603.67
1
4
9
5
4
1.2E-05
5
13
26
14
12
Page: 50
7.4
SHPP/GTZ
An anchor block is a gravity retaining structure placed at every sharp change along the penstock
pipe and is designed to retain penstock pipe movement in all directions. It should be stable against
overturning, sliding and sinking/bearing. Although the design of anchor blocks and saddles are site
and user specific and the rules of thumb are valid for micro-hydropower schemes, care should be
taken while using these rules of thumbs even for micro-hydropower projects. The spreadsheet
AnchorLoads is useful for calculating static and dynamic forces on an anchor block. In case the
penstock pipes upstream and downstream of an anchor block are not on a single plane (i.e., 3
dimensional forces), the resultant forces act on three dimensions and the block has to be stable in all
three dimensions. Calculation and design of anchor blocks for three dimensions is a complex
process and beyond the scope of this book and most of micro and mini hydropower projects have
penstock in single planes, therefore, a spreadsheet useful for calculating forces in a single plane
parallel to longitudinal section of the anchor block is presented. Moreover, the designers are strongly
advised to align penstock in a single plane.
AEPC/ESAP does not have any mandatory procedures for designing anchor blocks. Therefore,
standard procedures for calculating forces on anchor blocks are considered in this spreadsheet. The
possible forces acting on anchor blocks are presented in the spreadsheet.
Since the calculation of anchor forces consists of single line formula calculations without many
conditions, the spreadsheet is designed to present simple definitions of these forces along with
sketches, their formulae and the calculated results. An example of 500kW Jhankre mini-hydropower
project anchor block presented in Civil Works Guidelines for Micro-Hydropower in Nepal has been
taken as an example. Some additional forces are added and some of the formulae based on
analytical method are used.
7.4.1
Program example
Input for the cited example are presented in Figure 7.4. Elevations are used to calculate vertical angles ( a
and b ) in case these angles are not entered as inputs. As always, care should be taken to verify inputs in
red colour.
Total head,
Static head h gross = forebay water level pipe centre line = 650.50 636.750 = 13.750m
htotal = h gross + hsurge = 13.750 m + 48 m = 108 m
Unit weight of pipe and water,
Wp = (d + t) t gsteel = x 0.454 x 0.004 x 77 = 0.448 kN/m
2
Ww = (d ) /4* gwater =
P(0.450) 2
4
SHPP/GTZ
2. Axial frictional force of pipe on saddle supports transferred to anchor block considering f = 0.25 for steel
on steel (greased) saddle top.
Frictional force per support pier = f *W T*L2u cos a = 0.25*2.00 * 4 cos 13= 1.95 kN
Total frictional force for 8 piers (F2u ) = 1.95 x 8 = 15.653 kN
Note that F2d is zero since an expansion joint is located immediately downstream of the anchor block.
3. Hydrostatic pressure at bend due to the vector difference of static pressure and acting towards IP (F3)
and total force along the pipe (P). Since upstream and downstream penstock diameter are the same.
Pu (kN) = /4*d2*Ht*g = /4*.452*108*9.81 = 168.50
25 - 13
F3 = 2*P*sin((b-a)/2) = 2 x 168.50 x sin
= 35.227 kN
2
sin
sin
F8 = 2.5 d2 2 = 2.5
= 0.261 kN
0.450 2
2
9. No reducer is provided in this case. Therefore axial force on reduce (F9 = 0). In case there is a reducer,
total head at the specified reducer location is calculated for calculating F9.
10. Axial drag of flowing water (friction of flowing water) is generally not considered in micro and mini
hydropower scheme penstock design. Therefore F10 =0 is considered in this example.
11. Force due to soil pressure (F11):
2
g h
F11= soil 1 cos i x Ka x w
2
3
=0.371
20 18
. 2
cos 13 x 0.371 x 2 = 23.455 kN
2
This force acts at 1/3 of the buried depth at upstream face of anchor block, which is (1/3 x 1.8) = 0.6 m.
Page: 52
SHPP/GTZ
Summary of forces are presented in Figure 7.4. The forces calculated above are further resolved in
mutually perpendicular directions to get the summary. A typical calculation is presented in Table 7.2.
Forces acting at the bend and the total forces for both the expansion and contraction are presented in the
table. The total forces will further be utilized in anchor block design. These forces are calculated for
vertical angles of a = 13, b = 25.
F4u = 2.97
F4d = 2.97
F5u = 0.000
F5d = 0.000
F6u = 45
F6d = 45
F7u = 5.70
F7d = 6.08
F8 = 0.26
X - component (kN) +
= - F1u sin a = - 0.880
= - F1d sin b = - 1.538
= F2u cos a = 15.252
Y- component (kN) +
= F1u cos a = 3.813
= F1d cos b = 3.299
= F2u sin a = 3.521
b + a
= 11.469
2
b + a
= - 33.308
2
= F3 sin
= - F3 cos
= F8 sin
b + a
= 0.085
2
= - F8 cos
b + a
= - 0.247
2
F9u = 0.000
F9d = 0.000
F10u = 0.000
F10d = 0.000
F11 = 23.45
F12 = 354.64
SUM
(expansion)
SUM
(contraction)
Convex
Date
Revision
Project
Developer
Consultant
Designed
Checked
24-May-2006
2006.05
Jhankre mini-hydropower
BPC Hydroconsult
Input
Particulars
Upstream
Pipe dimensions
Diameter (Di)
Thickness
Shaddle Spacing & number
Central
0.45
0.004
4.00
Output
Weight of pipe, Wp (kN/m)
Weight of water, Ww (kN/m)
Total weight, W (kN/m))
Velocity, v (m/s)
Vertical angles, a & b (rad)
0.45
0.004
4.00
34.000
40.000
13.0000
25.0000
Yes
Yes
0.448
1.560
2.008
2.829
0.226893
0.45
78.5
9.81
25
Anchor Block
Soil
636.750
Elevations
Downstream
0.448
1.560
2.008
2.829
0.436332
22
200
30 0.5236
20
Heads (m)
Forebay WL
696.750
Tot.Transient Len
3277.753
Sumof Pipe Len (forebay to Anchor
1074.814
Block)
Total Surge Head
146.381
Static Head
60.000
Surge Head
48.00
Total (H)
108.000
Youngs Modulus of Elasticity (E2.1E
)
+11
Coefficient of Linear Expansion (12E-06
Page: 53
SHPP/GTZ
GENERAL FORCES
1. Perpendicular component of Wt of pipe and water act perpendicular to the pipe CL along the anchor faces
L'
a
FEMu
FEMd
F2
2.677
F1 u
F1 d
-2.677
F2 (kN)= m*w*L'*cos a
US Pipe Length, L' (m):
0.25
34.89
F2 (kN) =
3. Hydrostatic Pressure at Bend due to the vector difference of static pressure & acting towards IP
Pu (kN) = F3u =PI/4*dui^2*Ht*g
168.50
F3
168.50
F3 = 2*P*sin((b-a)/2)
pu
35.227
pd
L'
F4
3.112
0.757
F4=w sin a
W
F5 expansion
+ Expansion, - Contraction
Tmax
Tinstallation
40
20
0.000
F5 contraction
Tmin
F5
4
0.000
0.000
F5
0.000
6. Axial friction within Expansion joint seal due to the movement against the circumferential pressure
F6=PI()*D*W*H*g*m
+ Expansion, - Contraction
52.150
61.69
46.442
48.20
Total (AH)
98.592
109.888
55.666
60.959
F6 (kN)
F6
F6
F6
Pipe Movement
F7
5.518
6.042
F7
P8 (kN)
P8= mV =Q*r*Vi
1.273
F8
F9 (kN)
Fv
Q*r*Vo
F9
No
No
0.000
FH
Q*r* Vi
F9=PI()*(Dupi^2-Ddni^2)/4*g*H
3.00
59.33
47.97
F8
1.273
0.261
- Q*r*Vo
Q*r* Vi
F7
0.40
4.00
61.69
48.08
F9
0.40
0.000
Page: 54
SHPP/GTZ
10 Axial drag of flowing Water (friction of flowing water) (not considered in MHP)
F10=g*PI()*Dupi^2/4*DH(Exp to block)
F10 (kN)
0.000 No
0.000 No
11 Axial (u/s slope) force due to soil pressure upstreamof the block
F11 =gs*hs^2/2*cos f*ka*B
F 11
ka= (cosi-sqrt(cosi^2-cosf^2))/(cosi+sqrt(cosi^2-cosf^2))
hs = soil depth = hu
F11
0.371
1.8
23.455 Yes
Width, B(m)
@ 1/3 of hs
0.6
16.12
354.640 Yes
Expansion
12
Contraction
@ bend
Total
@ bend
Total
26.997
49.851
-1.49
21.37
-36.454
323.462
-17.02
342.90
0.000
0.00
7.5
A design of one of the anchor blocks of 500kW Jhankre minihydropower project presented in Civil Works Guidelines for
Micro-Hydropower in Nepal has been taken as an example
for preparing the spreadsheet AnchorBlock. It is worth
noting that the slight differences in calculated output in the
guidelines are mainly due to the rounding off of processed
data for secondary processing. A typical sketch of the
considered anchor block is presented in Figure 7.5. Stepwise
calculations of the considered example are also presented in
this section. The inputs for the calculations are presented in
the input section of the spreadsheet presented in Figure 7.7.
Figure 7.5: Anchor Block Considered
The spreadsheet is also designed to accommodate forces due to the dead weight of anchor block and
upstream earth pressure. In case forces at the pipe bend calculated as per section 7.4 are used, dead
weight of anchor block and upstream earth pressure for a different anchor block (not similar to defined in
AnchorLoads) can be used in this spreadsheet.
7.5.1
Program example
Concrete Block
Centre of gravity of the block from the upstream face of the block taking the moment of mass.
{(3 x 2.25)3/2 + (1/2 x 3 x 1.05)1/3 x 3} x 2
= 1.405m
{(3 x 2.25 ) + (1 / 2 x 3 x 1.05)} x 2
\ the weight of the block WB acts 1.41 m from point O.
Concrete volume (V) = Block volume excluding volume of the pipe and water if any
1
2
2
3
. } x 2 - 1 x P x 0.458 /4 cos 13 - 2 x P x 0.458 /4 cos 25 = 16.191 m
= {(2.25 x 3) + 3 105
2
Page: 55
SHPP/GTZ
Soil
Ka =
F11=
=0.3715
2
20 18
. 2
g soilh1
cos i x Ka x w =
cos 13 x 0.3715 x 2 = 23.455 kN
2
2
This force acts at 1/3 of the buried depth at upstream face of anchor block from point O as shown in Figure
7.6, which is (1/3 x 1.8) = 0.6 m. Perpendicular components of this forces are:
F11X= F11 *cos i = 23.455*cos 13 = 22.853 kN
F11Y= F11 *sin i = 23.455*sin 13 = 5.276 kN
M 563.303
= 1.632 m
=
V 345.26
e=
3
- 1.632 = 0.132 m
2
Lbase 3
= = 0.5 m
6
6
\ e < eallowable OK
eallowable =
Contraction case
Sum of moments about point O with clockwise moments as positive:
M @ O = -6.19 x 2.15 + 22.85 x 0.6 + 356.199 x 1.405 41.03 x 1.0 = 473.281 kN m
M 473.281
= 1.477 m
=
V 320.44
3
e=
- 1.477 = 0.023 m
2
d=
V
A base
6e
1 +
L
base
345.26 6 0.132
2
1 +
= 72.681 N/m
3 2
3
Page: 56
Pbase min =
V
Abase
6e
1 Lbase
SHPP/GTZ
345.26 6 0.132
2
=
1 = 42.406 N/m
3
2
3
Contraction case:
320.44 6 0.023
2
1 +
= 55.866 N/m
3 2
3
Pbase max =
V
A base
6e
1 +
L
base
Pbase min =
V
Abase
6e
1 Lbase
320.44 6 0.023
2
=
1 = 50.947 N/m
3 2
3
SHPP/GTZ
Date
24-May-2006
2006.05
Project
Developer
Consultant
Designed
Checked
Jhankre mini-hydropower
BPC Hydroconsult
Input
Anchor
Upstreamdepth, Hu (m)
Downstreamdepth, Hd (m)
Width, W (m)
Length, L (m)
g anchor (kN/m3)
m
Penstock
Bend at (X), (m)
Bend at (Y), (m)
Diameter, d (m)
Upstreamangle, a (deg)
Upstreamangle, b (deg)
Output
3.3
2.25
2
3
22
0.5
3.0
Pipe CL
2.5
2.0
1
2.15
0.458
13
25
1.5
1.0
0.5
Lengt h X ( m) '
0.0
-0.5
Foundation
Upstreamdepth hfu (m)
Soil friction f, (deg)
g soil (kN/m3)
Bearing Capacity, SBC (kN/m2)
1.8
30
20
200
0.0
0.5
Contraction
SH (kN)
SV (kN)
1.0
1.5
2.0
2.5
Soil force
Acting at (m)
3.0
3.5
4.0
0.3715
F Pa
16.191
356.199
1.405
Fx
23.455
0.6
22.853
Fy
5.276
Overturning
Net Forces
@ bend
SM@ O
53.180
30.327 d
345.260
-16.215 eccentricity e, Ok
e allowable
563.303 P max
1.632 P min
0.132
0.500
72.681 172.63
42.406 Ok
Ok
SM@ O
-6.19 d
-41.03 eccentricity e, Ok
473.281 P max
1.477 P min
0.023
55.866 160.22
50.947 Ok
Ok
16.66
320.44
Bearing
Sliding
Page: 58
SHPP/GTZ
8 TURBINE SELECTION
8.1
GENERAL
A turbine converts potential energy of water to rotational mechanical energy. Cross-flow and Pelton
turbines are the most commonly used turbines in Nepali micro hydropower plants. Pelton, Francis and
Turgo turbines are used in mini and small hydropower projects. The size and type of turbine for a
particular site depends on the net head and the design flow. Pelton turbines are suitable where the ratio of
head to flow is high. For Cross-flow and Francis turbines, this ratio is lower than that of the Pelton
turbines. Turgo turbines lie in between these two categories. It should be noted that for certain head and
flow ranges, both Pelton (multi-jet) and other turbines may be appropriate. In such cases, the designer
should consult with manufacturer and make a decision based on availability, efficiency and costs. On a
horizontal shaft Pelton turbine the maximum number of jets should be limited to 3 for ease of
manufacturing. The number of jets can be higher for vertical shaft Pelton turbines. However, these require
higher precision work in mounting the generator vertically on the turbine shaft and furthermore, in case of
varying rotational speeds (RPM of the turbine and the generator), the belt drive arrangements (including
those for mechanically coupled end uses) will be difficult.
8.2
GENERAL RECOMMENDATIONS
The recommended net heads for maximum rotational speed (rpm) and efficiencies for different turbines
and turbine specifications are presented in Table 8.1.
Table 8.1: Turbine specifications
Type
Net head (m)
Pelton
More than 10m
T12 Crossflow
up to 50m
T15 Crossflow
up to 80m
Max RPM
1500
900
1500
Efficiency (nt)
70 - 75%
60 - 78%
60 - 78%
The type of turbine can be determined by its specific speed given by the following equation:
Sp Speed (no gear) ns = Turbine rpm*(1.4*PkW/Nturbines)/Hn5/4
Sp Speed (gear) nsg = Sp Speed (no gear)* Turbine rpm / Generator rpm
Table 8.2: Turbine type vs. ns
Turbine types
Single Jet Pelton
Double Jet Pelton
Three Jet Pelton
Cross flow
ns Ranges
10 30
30 40
40 50
20 80
Page: 59
8.3
SHPP/GTZ
The Turbine spreadsheet is presented in Figure 8.2. The specific speeds (ns) with (gear ratio of 1:2) and
without gear are calculated as:
5/4
If ns exceeds the range given in Table 8.2, multiple units should be used. Specific speed of multijet Pelton turbines is computed by multiplying the specific speed of runner by the square root of the
number of the jets. The calculations show that for the given parameters, either a gearless
Crossflow/Turgo turbine or a Pelton/Crossflow with a gear ratio of 1:2 is recommended.
Turbine Selection
Small Hydropower Promotion Project (SHPP)/GTZ
Referances: 6,7,8,12,13
25-Apr-2006
2006.03
Date
Project
Developer
Consultant
Designed
Checked
Pushpa Chitrakar
Pushpa Chitrakar
Input
Discharge (l/s)
Gross head (m)
Hydraulic losses
Max turbine output kW
Turbine rpm
Cd
Output
Net head m
No Gearing
Sp speed of runner rpm (no gearing)
Pelton (12-30) => (Ns 17-42)
Turgo (Ns 20-70) => (Ns 28-99)
Crossflow (Ns 20-80)
Fracis (Ns 80-400)
Propeller or Kaplan (Ns 340-1000)
1
2
1
2
Pelton
0.46
**
Turgo
Crossflow
**
**
1500
With Gearing
46 Sp speed of turbine
Pelton (12-30) => (Ns 17-42)
Turgo (Ns 20-70) => (Ns 28-99)
Crossflow (Ns 20-80)
Fracis (Ns 80-400)
Propeller or Kaplan (Ns 340-1000)
23
Pelton
**
Crossflow
**
**
Page: 60
SHPP/GTZ
GENERAL
A generator converts mechanical energy to electrical energy. There are two types of generators; namely,
synchronous and asynchronous (induction).
Generally, induction generators are inexpensive and appropriate for Nepali micro-hydro schemes up to
about 15kW. For micro-hydro schemes ranging from 10kW to 100kW, synchronous generators are
technically and economically more attractive. Both synchronous and asynchronous generators are
available in single and three phases. Brushless synchronous generators are recommended for mini and
small hydropower projects.
Load controllers are generally used as the governing system in Nepali micro hydro schemes. An
Electronic Load Controller (ELC) is used for controlling power output of a synchronous generator. To
control an induction generator, an Induction Generator Controller (IGC) is used. Brushless synchronous
generators with hydraulic controlling systems are recommended for mini and small hydropower projects.
9.2
Selection of generator size mainly depends up on the loads of a proposed site. Selection of generator
type depends on the size of the selected generator, nature of the proposed loads and costs and benefits
of the scheme. As stated earlier, a generator type can be either synchronous or induction of either single
or three phase. Some of the main features of all types of generator are outlined in the following sections:
9.2.1
9.2.2
Page: 61
SHPP/GTZ
9.3
GENERAL RECOMMENDATIONS
Based on the major features, general guidelines for selection of phase and type of generator are prepared
and summarized in Table 9.1.
Table 9.1: Selection of Generator Type
Size of scheme
Up to 10 kW
Generator
Synchronous/Induction
Phase
10 to 15 kW
Synchronous/Induction
More than 15 kW
Synchronous
Three Phase
Three Phase
Maximum ambient temperature, powerhouse altitude, electronic load controller correction factor and
power factor of the proposed loads are the major factors affecting the size of a generator. De-rating
coefficients to allow for these factors are presented in the Table 9.2.
Table 9.2: Generator rating factors
Max. Ambient temperature in oC =>
Temperature Factor (A)
Altitudes
Altitude
Factor
(B)
20
1.10
25
1.08
30
1.06
35
1.03
40
1.00
45
0.96
50
0.92
55
0.88
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
4500
1.00
0.98
0.96
0.945
0.93
0.915
0.90
0.88
0.86
0.845
0.83
0.815
0.8
0.785
0.77
0.83
For light bulb loads (inductive) only
For mixed loads of tube lights and other inductive loads
1.0
0.8
ii) Handling of starting current if large motors (> 10% of generator size) are supplied from the
generator.
iii) The generator running at full load when using an ELC.
3
120 f
P
Where,
Page: 62
SHPP/GTZ
It is worth noting that an induction generator is basically a motor used as a generator. Similar to
motor rating, the rating of an induction generato should be in kW. Therefore, ELC factor (C) and
the power factor (D) corrections are not applicable for an induction generator. Other factors are
applied similar to a sychronous generator. Generator voltage and current ratings should not
exceed 80% of the electrical motor rating.
2
120 f
(1 + s )
P
Where,
P and f are the same as for synchronous generator and
s is the slip of the generator,
s=
Ns - Nr
Ns
Where,
Ns is the synchronous speed, i.e. Ns( RPM ) =
120 f
P
Nr is the rated rotor speed of the induction motor and Ni always exceeds Ns while
acting as a generator.
9.4
Sizing of electrical load controller (ELC) or induction generator controller (IGC) (equal to the
installed capacity).
Sizing of ballast (20% higher than the installed capacity). In case the installed capacity exceeds or
equal to 50kW, the ballast capacity of ELC-Extension is calculated as:
Ballast capacity of ELC extension (kW) = 60% * 1.2 * Pe (electrical power)
Fixed load = 40% * Pe (electrical power)
Sizing of MCCB/MCB.
Page: 63
SHPP/GTZ
Rotational speed ( N ) =
120 f
RPM =120*50/4
P
= 1500 rpm
Since Pe > 50kW, the ballast capacity of ELC extension (kW) = 60% * 1.2 * Pe + 40% * Pe
= 0.6*1.2*60.04 + 0.4*60.04
= 67.24 kW
I rated for Cable & MCCB at Generator side = 1000/ V rated * Generator size /1.732
= 1000 / 400*140/1.732
= 202.08 Amp
Page: 64
SHPP/GTZ
For this current a 4-core copper armoured cable of ASCR 185mm is chosen.
11-Nov-2005
2005.10
SMALL HYDROPOWER PROMOTION PR
Revision
OJECT/G
TZ
Project
Upper Jogmai, Ilam
Developer
Kankaimai Hydropower P Ltd
Consultant
EPC Consult
Designed
Pushpa Chitrakar
Checked
Pushpa Chitrakar
Referances: 6,7,8,12,13
Date
INPUT
3
Discharge (m /s)
Gross head (m)
Overall plant efficiency (%)
o
Temperature ( C)
Altitude (m)
ELC correction factor
Frequency of the system (Hz)
Capacity of used generator (kVA)
0.8
1.3
3-phase 3
45 Type of Generator
1500 Over rating factor of MCCB
0.83 Over rating factor of cable
50 No. of poles
0 Rated rotor speed if induction generator N (rpm)
Delta
Synchronous
1
1.25
1.5
OUTPUT
Pe Electrical output (active power) (kW)
Generator
Temp.factor
Capacity (kVA)
Synchronous rotational speed Ns (rpm)
ELC capacity (kW)
60.04 Ok
0.96
140.00
72.04
67.24
Cable
Rating (A)
202.08
135.40
185
Page: 65
SHPP/GTZ
Rotational speed ( N ) =
120 f
=120*50/4
P
= 1500 rpm
Rotational speed of a generator = Ns*(1+(Ns-N)/Ns) = 1500*(1+(1500-1450)/1500)
= 1550 rpm
Excitation capacitance
-1
1000*Pe* sin (cos (power factor))
C (F) = ----------------------------------------------------2
3*V *pf*2*pi()*f*hm
-1
For this current a 2-core copper armoured cable of ASCR 185mm is chosen.
Page: 66
SHPP/GTZ
11-Nov-2005
2005.10
SMALL HYDROPOWER PROMOTION PR
Revision
OJECT/G
TZ
Project
Upper Jogmai, Ilam
Developer
Kankaimai Hydropower P Ltd
Consultant
EPC Consult
Designed
Pushpa Chitrakar
Checked
Pushpa Chitrakar
Referances: 6,7,8,12,13
Date
INPUT
3
Discharge (m /s)
Gross head (m)
Overall plant efficiency (%)
o
Temperature ( C)
Altitude (m)
ELC correction factor
Frequency of the system (Hz)
Capacity of used generator (kW)
Capacitor configuration
0.8
1.3
1-phase 1
45 Type of Generator
1500 Over rating factor of MCCB
0.83 Over rating factor of cable
50 No. of poles
0 Rated rotor speed if induction generator N (rpm)
Delta
Efficiency of motor at full load
Induction
2
1.25
1.5
4
1450
89%
OUTPUT
Pe Electrical output (active power) (kW)
Generator
Temp.factor
Capacity (kW)
Synchronous rotational speed Ns (rpm)
0.96
30.00
1550
24.00
123.16
Cable
Rating (A)
170.45
142.04
150
Page: 67
SHPP/GTZ
10 MACHINE FOUNDATION
10.1
A machine foundation of a hydropower scheme is a gravity structure designed to transfer hydraulic forces
from penstock, torque from rotating machines and gravity loads from generator, turbines and the
foundation itself. Similar to an anchor block, the machine foundation should be stable against overturning,
sliding and sinking/bearing. Standard dimensions can be referred to while dimensioning microhydropower machine foundation. It is strongly recommended to refer to suppliers while dimensioning mini
and small hydropower machine foundations.
A machine foundation of 500kW Jhakre Mini-hydropower project cited in Civil Works Guidelines for MicroHydropower in Nepal has been taken as an example in the spreadsheet MachineFoundation. A plan
and a section of the considered foundation are presented in Figure 10.1. These figures are part of the
presented spreadsheet and are interactive diagrams. The considered machine foundation is designed to
support a directly coupled Pelton turbine and a generator.
It is worth noting that the critical plane of a machine foundation depends on turbine axis and coupling
types. A turbine axis (shaft) is perpendicular to the incoming flow for Crossflow, Pelton and Spiral case
Francis turbines whereas it is parallel to the incoming flow for open flume Francis and other axial flow
turbines. Coupling type (direct or belt drive) also determine a critical plane (XX or YY as presented in the
spreadsheet) with respect to its stability. Stability along both these mutually perpendicular axes are
analysed in the presented spreadsheet. Stepwise calculations of the considered example are presented
in the following sections. For input to these stepwise calculations, refer to the input section of the
spreadsheet is presented in Figure 10.1.
10.2
EXAMPLE
General Calculations
htotal
= hgross + hsurge = 51 m + 50 m
= 101 m:
0.3 2
m 2 101 m 9.8 kN / m 3
4
= 70.036 kN
Weight of the three sections W1, W 2. W 3 as presented in Figure 10.1 are:
W1
= 0.4m 1.5m 2.5m 22kN/m3
=33.00 kN
W2
W3
Overturning:
Take sum of moments about point B (counter clockwise moments as positive):
0.4
0.45
2.35
SM@B = W 1 x
+ 0.45 + 2.35 + (W 2 + W T )
+ 2.35 + (W G + W3 )
- FH 1.8
2
2
2
Page: 68
SHPP/GTZ
M = 282.455 = 1.084 m
V 260.477
L Base
3.2
- d =
- 1.084 = 0.516 m
2
2
eccentricity,
eallowable =
e=
LBase 3.2
=
= 0.533 m
6
6
Pbase min =
V 1 +
A base
6e
=
Lbase
V 1 -
A base
6e
L base
260.477 6 0.516
2
1 +
= 64.038 kN/m
3.2 2.5
3.2
260.477 6 0.516
2
=
1 = 1.081 kN/m
3.2
2.5
3.2
Since both pressures are within zero and 180 kN/m (max. allowed for soil) the structure is safe against
sinking.
Sliding:
Assume that the friction coefficient between block and soil, m = 0.5
SH = FH = 70.036 kN
m SV = 0.5 x 260.5 = 130.2 kN
Factor of safety against sliding:
=
m V
130.238
= 1.86 > 1.5 OK
70.036
Stability along YY is analysed in similar manner. It is worth noting that the machine foundation is not
stable (for the stated factor of safety) against overturning and bearing along YY axis and this is the real
critical case for the presented example in the guidelines. However, this critical case is not considered and
not illustrated in the guidelines. The mismatch between Photo 8.4 (the actual case) and Figures 8.2 to 8.4
is quite noticeable. The Pelton turbine axis in Photo 8.4 perpendicular to XX axis (longer) whereas it is
considered parallel to XX axis in the illustrated calculations.
Page: 69
SHPP/GTZ
Date
24-May-2006
2006.05
Jhankre mini-hydropower
Project
Developer
Consultant
Designed
Checked
BPC Hydroconsult
1.8
1.6
1.2
YY (m)
Height ZZ (m)
1.4
1.0
0.8
Turbine CL
Generator CL
0.6
0.4
0.2
0.0
W1
W2
W3
2.8
2.6
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
Turbine CL
Generator CL
XX (m)
XX (m)
INPUT
Gross head hg (m)
Surge head hs (m)
Foundation
0.150
Penstock
Foundation on
2
Soil
Diameter dp (m)
0.300
180
Material
0.5
Centreline above PH floor hp (m)
3.2 Turbine Pit
2.5
Length of opening Lo (m)
1.5
Bredth of opening Bo (m)
Concrete
Height of opening Ho (m)
mild steel
0.300
0.450
0.500
1.000
22
0.500
Electro-mechanical
Weight of turbine Wt (kN) & cl position
Weight of generator Wg (kN) & cl position
2.943
3.434
XX (m)
0.625
2.025
YY (m)
1.250
1.250
Weight Wi
(kN)
70.036
LA along YY
33.000
27.225
193.875
3.000
2.575
1.175
282.455
260.477
1.25
1.25
1.25
199.530
260.477
OUTPUT
Forces
Force due to h total of 101 m, Fh (kN)
Foundation
W1
W2
W3
Sum of moments SM (kN-m)
Sum of vertical forces SM (kN)
Page: 70
SHPP/GTZ
Overturning
Equivalent distance at which SM acts from critical point
d (m)
Eccentricity e, (m)
Allowable eccentricity e all (m)
Comment on overturning moment
LA along XX
1.084
0.516
0.533
Ok
LA along YY
0.766
0.484
0.417
Not Ok
Bearing
Pressure at base
Pmax
Pmin
Comments on bearing
LA along XX
64.038
1.081
Ok
LA along YY
70.379
-5.260
Not Ok
LA along XX
1.860
Ok
LA along YY
1.860
Ok
Sliding
Factor of safety against sliding, FS sl
Comment of sliding
Page: 71
SHPP/GTZ
Power generated at a powerhouse is evacuated to load centres or grids with the help of transmission and
distribution lines. According to the Nepal Standards, 400/230V is the standard minimum voltage.
400/11000V system is used in micro-hydropower transmission system where as 11 kV/33 kV is used in
mini and small hydropower transmission system. 11 kV and 33 kV are also considered to be distribution
voltage by Nepal Electricity Authority (NEA). Use of standard voltages in micro hydropower projects is
recommended so that the power can be easily synchronized and evacuated to grid in future.
11.2
GENERAL RECOMMENDATIONS
AEPC MGSP/ESAP has formulated following guidelines regarding micro-hydropower transmission and
distribution systems:
1
Cable configuration and poles: Buried or suspended on wooden or steel or concrete poles.
Conductor: Aluminum conductor steel reinforced (ACSR) or Arial Bundled Cable (ABC)
Type of
ACSR
Squirrel
Gopher
Weasel
Rabbit
Otter
Dog
Resistance
Ohm/km
1.374
1.098
0.9116
0.5449
0.3434
0.2745
Current
rating max
Amps
76
85
95
135
185
205
Equivalent
Copper area
2
mm
13
16
20
30
50
65
Inductive
Reactance
Ohm/km
0.355
0.349
0.345
0.335
0.328
0.315
Sp.
Weight
(kg/km)
80
106
128
214
Sp. Cost
(Rs/km)
13000
14500
15500
25750
394
52000
Note: Sp. Costs are taken from the guidelines and are lower than the market price. It is recommended to refer to the actual market price in the
design.
11.3
The presented spreadsheet is designed to calculate transmission parameters for three phase
33kV, 11kV and 400V and single phase 230V transmission and distribution lines.
Balanced load is assumed, i.e., neutral conductor does not carry any current.
With a power factor of 0.8, the rated current and voltage drop are calculated as:
Table 11.2: Rated current and voltage drop calculation
Phase
3-phase
1-phase
Current (A)
Power*1000/(1.732*V* power factor)
Power*1000/(V*power factor)
SHPP/GTZ
Vprevious/1.732 - dV
Spreadsheet protection: Transmission line networks is project specific and does not match each
other. Therefore, this spreadsheet is not protected to match the transmission line networks of the
considered project.
Start
Project
Name,
Location,
Length of cables
Cost of cables
Length
of
neutral
cables
Current
Resistance
Reactance
Impedance
Voltage drop
Voltage at node
End
Figure 11.1: Flow chart of transmission and distribution line computation.
The grid and load presented in Figure 11.2 are used for the calculations presented in Figure 11.3.
Transformer # 1
Legends
Node/Load (kW) at nodes
Reach length (m)/Phase/Load (kW)
Figure 11.2: Transmission line and load used for the example.
Page: 73
SHPP/GTZ
SHPP/GTZ
Project:
Developer
Consultant
Designed
Checked
20-Apr-2006
Date
Revision 2006.03
Cable Summary
Type
Squirrel
Gopher
Weasel
Rabbit
Otter
Dog
Total Cost(Rs)
Node name
Reach
name
Reach
Length
(km)
Length(km)
7.02
10.00
2.36
1.55
2.40
486080.00
PH-A-B-C-D
PH
A
A
B
C
D
PHA
AB
AC
AD
0.300
0.500
0.090
0.090
3
3
1
1
1
16
5
5
6
400.00
28.87
27.50
29.80
33.50
400.00
393.70
393.70
393.70
393.70
400.00
400.00
227.30
227.30
227.30
6.30
17.60
3.40
3.90
400.00
393.70
209.70
223.90
223.40
1.58
10.40
2.65
2.87
PH-T1
PH
T1
PHT1
0.050
3
3
20 Otter
400.00
36.08
400.00
400.00
400.00
400.00
1.50
400.00
398.50
0.38
T1-T2
T1
T2
T1 T2
1.500
11
11
11000.00 11000.00
1.31 11000.00
11000.00
11000.00
4.70
11000.00
10995.30
0.04
T2-E
T2
T2 E
0.300
3
3
20 Dog
400.00
36.08
400.00
400.00
400.00
400.00
7.80
400.00
392.20
1.95
E-J ( r )
T2
J
T2 J
0.300
1
1
20 Dog
226.44
110.41
226.44
226.44
226.44
226.44
27.70
226.44
198.74
13.59
E-H (y)
E
F
F
H
EF
FH
0.300
0.400
1
1
1
6 Otter
5 Otter
226.44
33.12
28.80
226.44
217.04
217.04
226.44
226.44
217.04
9.40
10.90
226.44
217.04
206.14
5.64
16.01
E-G (b)
E
F
F
G
EF
FG
0.300
0.200
1
1
1
7 Rabbit
5 Rabbit
226.44
38.64
29.53
226.44
211.64
211.64
226.44
226.44
211.64
14.80
7.60
226.44
211.64
204.04
7.98
19.27
E-M ( r)
E
F
F
M
EF
FM
0.300
0.600
1
1
1
1 Squirrel
1 Squirrel
226.44
5.52
5.63
226.44
221.84
221.84
226.44
226.44
221.84
4.60
9.40
226.44
221.84
212.44
3.55
11.19
F-K (y)
F
K
FK
0.180
1
1
2 Squirrel
217.04
11.52
217.04
217.04
217.04
217.04
5.80
217.04
211.24
8.16
F-L(b)
F
L
FL
0.180
1
1
1 Squirrel
211.64
5.91
211.64
211.64
211.64
211.64
3.00
211.64
208.64
9.29
Dog
Rabbit
Rabbit
Rabbit
20 Squirrel
Page: 75
SHPP/GTZ
10
Squirrel
Gopher
Weasel
Rabbiit
Otter
Dog
0.90
1.00
0.18
0.18
0.15
4.50
0.90
0.60
0.60
0.80
0.60
0.40
0.60
1.20
0.36
0.36
Page: 76
SHPP/GTZ
GENERAL
By optimising the use of available energy by allocating it in different time slots, benefit from a micro hydro
scheme can be maximized. Based on the AEPC MGSP/ESAP guidelines, a spreadsheet on loads and
benefits is presented for concerned stakeholders to arrive to the most optimum pre-construction decision.
12.2
12.3
Start
Project
Name,
Location,
Installed capacity,
present loads & tariff (24 hr, 5 slots)
Future EU load & tariff (1 time slot)
24 hr load
Load duration
Graph (decision making)
Annual energy
Yearly loads
EU factors
Yearly income
End
Figure 12.1: Flow chart of the load and benefits calculation spreadsheet.
Page: 77
SHPP/GTZ
Load Duration Chart for the first three years of operation of Gaddi
Gad Khola
2
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
140
120
100
80
60
40
20
0
0
10
11
12
13
14
15
16
17
18
19
20
21
22
Time (hrs)
Domestic
Agro-processing
Bakery
Saw Mill
Herbs Processing
Load 5
Load 6
Installed Capacity
23
SHPP/GTZ
Date
Revision
Project:
20-Apr-2006
2006.03
Ladagada VDC, Doti
Location:
Developer
Consultant
Designed
Checked
INPUT
General
Power Output (kW)
Name of the Source
96.1
Gaddi Gad Khola
Beneficiary HH (nos.)
Plant's operating days
471
330
Operating Tariff
days/year
(Rs)
330
1.00
330
6.00
320
6.00
300
5.00
180
5.50
330
330
Domestic lighting
Average subscription/household (W/HH)
System loss
10%
time
5
load
88
440
Probable Business Load Expected after 3 years
Operating d/y Tariff (Rs)
Load
Metal Workshop
330
6.00
Photo Studio
320
6.00
Dairy Processing
320
6.00
Cold Store
310
6.00
Load 5
Load 6
12
22.5
14
16
22
18
22
18
22
17
22
16
10
12
25
8
15
22
10
22
8
9
3
3
85
8
10
1
8
6
18
91.1
182.2
36.00
761112
End Use
Load
Operation Period
Yearly Load
Annual
(kW)
Hours/day Days/year
kWh
LF (%)
Income (Rs)
Domestic Lighting
44.483
13.987
330
205326
26.98
480,420
Existing/Committed Business Load
Agro-processing
22.5
4
330
29700
3.90
178200
Bakery
9
6
320
17280
2.27
103680
Saw Mill
10
2
300
6000
0.79
30000
Herbs Processing
25
5
180
22500
2.96
123750
Load 5
15
6
330
29700
3.90
Load 6
12
3
330
11880
1.56
Total
117060
15.38
435,630
Total Annual Income from sales of electricity
916,050
Probable Business Load after 3 years
Metal Workshop
10
Photo Studio
1
Dairy Processing
8
Cold Store
6
Load 5
Load 6
Total additional annual income after 3 years
Productive End Use (%)
19.40
4
12
10
10
330
320
320
310
13200
3840
25600
18600
1.73
0.50
3.36
2.44
61240
8.05
20
79200
23040
153600
111600
183,720
1037
378578
49.97%
SHPP/GTZ
As per the guidelines and standards set aside by AEPC, this spreadsheet tests financial viability of a
micro-hydro scheme for the subsidy approval. The base of the robustness of the project is mainly its
financial sustainability during its life span of 15 years. Positive Net Present Value (NPV) of project cost
(equity) and benefit streams based on based on 4% of discount rate is expected for subsidy approval.
13.2
1. 15 years as the economic life span of the project for calculating financial parameters.
2. Total cost of the project including subsidy should be limited to
Table 13.1: Per kilowatt subsidy and cost ceiling as per AEPC
Walking distance from nearest road
head
less than 2 days walking distance
2-5 days walking distance
more than 5 days walking distance
Subsidy
70000
78750
91500
Ceiling
170000
178750
191500
13.3
Page: 80
SHPP/GTZ
Start
Sources of investment
Payback of loan
Discount factor
Breakdown of investment cost
Annual operating cost
Project
Name,
Location,
L i (1 + i ) n
(1 + i ) n - 1
Alternatively, an Excel built-in function PMT (interest rate, payback year, loan) can also be used to calculate
the annual installment. If the installment mode is other than annual (such as monthly and quarterly), it is
recommended to use Loan Payment module of the presented Utility spreadsheet.
Based on the projected annual cash flows (CFs), NPV of the project can be calculated by using following
equation.
NPV = CF0 +
CFn
CF1
CF2
+
+ ............. +
1
2
(1 + i )
(1 + i )
(1 + i ) n
=
t =0
CFt
(1 + i ) t
Page: 81
SHPP/GTZ
An alternative equivalent Excel built-in function NPV(Discount Factor, Cash Flows)*(1+Discount Factor) is
used in this spreadsheet. NPV of equity without probable business load is,
NPV equity = NPV(Discount Factor, Cash Flows)*(1+Discount Factor)
= NPV(4%, -1200000, 307682, ., 611046,)*(1+4%) = Rs. 3,773,038 OK since it is positive.
Cost per kilowatt = Total Project Cost / Project Size = 12,734,865/96.1 = Rs 132,517/kW OK since it is
within the limit Rs 191,500/kW for projects located with an access of five days or more of walking distance.
Based on above results, the project is financially viable for subsidy approval.
parameters for different cases are calculated in similar manner.
Date
23-Apr-2006
Revision
2006.03
Project
Developer
Consultant
Designed
Checked
INPUT
Project size (kW):
96.10
Total Project Cost (Rs.)
12,734,865
Subsidy/kW
Total subsidy
more than
5 days walking distance
91500 Rs/kW x 96.1 =
8793150
Interest rate i (%)
Payback period n (yr)
Plant life N (yr)
15
Discount Rate I (%)
4%
Investment Cost (Rs)
Mechanical components
Electrical component
Civil component
Spare parts & tools
Transport.
Bank loan
1,890,044
3%
7
Other loan
8,516,715
999,040 Installation
2,061,717 Commissioning
1,363,497 VAT
57,550 Contingencies
3,178,800 Others
Kind equity
851,671
Others
O & M (Rs)
Salary
Spares
Maintenance
Office expenses
Miscellaneous
Others
232,500
623,611
Cost Summary
Project cost (Rs)
Annual Operation, Maintenance and other Costs (Rs)
Annual Income without probable business loads (Rs)
Annual Income with probable business loads (Rs)
Annual installment for Bank loan
Annual installment for other loan
NPV on equity without probable business load (Rs)+ve
NPV equity with probable business load (Rs)+ve
Cost/Kw =>>Ok
Subsidy/HH
Cash equity
1,200,000
305,004
114000
171,000
20,004
12,734,865
305,004
916050
1099770
303364
NA
3,773,038
5,305,869
132,517
18,669
Equity
O & Mcosts
Loan repayment
Income
1,200,000
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
305,004
303,364
303,364
303,364
303,364
303,364
303,364
303,364
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
916,050
Cash flow
-1,200,000
307,682
307,682
307,682
307,682
307,682
307,682
307,682
611,046
611,046
611,046
611,046
611,046
611,046
611,046
611,046
916,050
916,050
916,050
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
1,099,770
Cash flow
-1,200,000
307,682
307,682
307,682
491,402
491,402
491,402
491,402
794,766
794,766
794,766
794,766
794,766
794,766
794,766
794,766
14
14.1
SHPP/GTZ
UTILITIES
INTRODUCTION
In this spreadsheet tools for independent calculations are presented. These tools are especially helpful in
case quick and handy independent computations are required. Some of the presented tools are:
14.1.1 Uniform depth of a rectangular or trapezoidal canal
Calculation of uniform depths of an open channel is an iterative process. Mannings equation is used for
calculating uniform depth. VBA for Excel is used for this iterative process. A typical calculation for a
trapezoidal section is presented in Figure 14.1.
Date
01-May-2006
Revision
2006.05
1,000
50.0000
300
Freeboard, FB (m)
0.2
0.3
1.000
Z= 0.50
1.572
0.572
Wall
Page: 83
SHPP/GTZ
Payment of a loan
Small Hydropower Promotion Project (SHPP)/GTZ Spreadsheet by Mr Pushpa Chitrakar
Date
01-May-2006
Revision
2006.05
1
Payback
Loan amount (NRs) :
2006
10
Yearly Payment
331,721.20
Back to Utilities
Generate Schedule
Pmt No.
Pmt
Principal
Interest
Balance
Feb-06
Feb-07
Feb-08
Feb-09
Feb-10
Feb-11
Feb-12
Feb-13
Feb-14
Feb-15
1
2
3
4
5
6
7
8
9
10
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 331,721
Rs 97,721
Rs 110,425
Rs 124,780
Rs 141,002
Rs 159,332
Rs 180,045
Rs 203,451
Rs 229,899
Rs 259,786
Rs 293,559
Rs 234,000
Rs 221,296
Rs 206,941
Rs 190,720
Rs 172,389
Rs 151,676
Rs 128,270
Rs 101,822
Rs 71,935
Rs 38,163
Rs 1,702,279
Rs 1,591,854
Rs 1,467,074
Rs 1,326,072
Rs 1,166,740
Rs 986,695
Rs 783,244
Rs 553,345
Rs 293,559
(Rs 0)
Date
01-May-2006
Revision
2006.05
Discharge (l/s):
Cumulative efficiency including head loss (n%)
120
80.00%
300.00
282.53
176.58
SHPP/GTZ
Date
15-Apr-2006
Revision
2006.03
2,000
500
300
1.5
1.5
8.11
17.21
Voltage Drop
Small Hydropower Promotion Project (SHPP)/GTZ Spreadsheet by Mr Pushpa Chitrakar
Date
01-May-2006
Revision
2006.05
1.000
230
Power, P (kW)
ASCR type
20
Dog
6.00
Current, I (A)
108.70
Impedence, Z (/km)
0.4178
151.34
3.42
78.66
%Voltage drop
39.49
Page: 85
SHPP/GTZ
2006.05
Revision
Discharge (m3/s)
Gross head (m)
Pipe roughness ks (mm)
Pipe diameter (mm)
Pipe Length (m)
Turbulent headloss factor (K)
Friction factor f
Headloss hl (m)
Headloss hl (%)
Net Head (m)
0.500 Flow
63 Velocity, v(m/s)
0.010 Reynold's nr, (R )
500.00 Laminar Flow
2.546479089
1116876.794
5.73027E-05
9.170E+00
9.170E+00
Transitional
Flow
&
Turbulent
Flow
0.011893135
0.0119
1.282
2.03
61.718
100
1.50
Page: 86
SHPP/GTZ
15 REFERENCES
1. Mini-Grid Support Programme, Alternative Energy Promotion Centre, Kathmandu, Nepal (2002),
Peltric Standards
2. Mini-Grid Support Programme, Alternative Energy Promotion Centre, Kathmandu, Nepal (2003),
Preliminary Feasibility Studies of Prospective Micro-hydro Projects
3. Mini-Grid Support Programme, Alternative Energy Promotion Centre , Kathmandu, Nepal(2001),
Technical Details and Cost Estimate
4. Mini-Grid Support Programme, Alternative Energy Promotion Centre , Kathmandu, Nepal(2003),
Guidelines for Detailed Feasibility Study of Micro-Hydro Projects
5. European Small Hydropower Association (1998), Layman's Guidebook on How to Develop a Small
Hydro Site
6. BPC Hydroconsult, Intermediate Technology Development Group (ITDG), Kathmandu, Nepal
(2002), Civil Works Guidelines for Micro-Hydropower in Nepal.
7. United Nations Industrial Development Organization (UNIDO), Report on Standardization of Civil
Works for Small Hydropower Plants
8. GTZ/Department of Energy Development, Energy Division, Papua New Guinea, Micro Hydropower
Training Modules (1994), Modules 1-7, 10, 13, 14 & 18B.
9. American Society of Civil Engineer (ASCE), Sediment Transportation.
10. KB Raina & SK Bhattacharya, New Age International (P) Ltd (1999), Electrical Design Estimating
and Costing.
11. Badri Ram & DN Vishwakarma, Tata McGraw-Hill Publishing Company Limited, New Delhi 1995,
Power System Protection and Switchgear, 1995.
12. Adam Harvey et.al. (1993), Micro-Hydro Design Manual, A guide to small-scale water power
schemes, Intermediate Technology Publications, ISBN 1 85339 103 4.
13. Allen R. Inversin (1986), Micro-Hydropower Sourcebook, A Practical Guide to Design and
Implementation in Developing Countries, NRECA International Foundation, 1800 Massachusetts
Avenue N. W., Washington, DC 20036.
14. Helmut Lauterjung/Gangolf Schmidt (1989), Planning of Intake Structures, GATE/GTZ, Vieweg.
15. HMG of Nepal, Ministry of Water Resources, Water and Energy Commission Secretariat,
Department of Hydrology and Meteorology, Methodologies for estimating hydrologic characteristics
of un-gauged locations in Nepal (1990).
16. HMG/N, Medium Irrigation Project, Design Manuals, 1982
17. His Majesty's Government of Nepal, Ministry of Water Resources, Department of Irrigation,
Planning and Design Strengthening Project (PDSP), United Nations Development Programme
(NEP/85/013) / World Bank, Design Manuals for Irrigation Projects in Nepal, 1990.
18. ITECO, DEH/SATA Salleri Chialsa Small Hydel Project (1983), Technical Report.
Page: 87
SHPP/GTZ
19. P.N. Khanna (1996), Indian Practical Civil Engineer's Handbook, 15th Edition, Engineer's
Publishers, Post Box 725, New Delhi - 110001.
20. ITDG, Electrical Guideline For Micro-Hydro Electric Installation.
21. REDP, REDP Publications, Environment Management Guidelines, 1997
22. ITDG, IT Nepal Publications, Financial Guidelines for Micro-hydro Projects, 1997
23. IT Nepal Publications, Management Guidelines For Isolated MH Plant In Nepal, 1999.
24. ITDG/ESAP, Guidelines relating to quality improvement of MH plants, 1999
25. ICIMOD, Manual for Survey and Layout Design of Private Micro Hydropower Plants.
26. Norwegian Water Resources and Energy Administration, The Norwegian Regulations for Planning,
Construction and Operation of Dams, Norwegian University Press, Oslo, Norway, 1994.
27. Various Consultants, AEPC subsidized Nepali micro-hydropower (up to 100kW) Pre-feasibility and
Feasibility Study Reports (about 400 projects), 2002-2004.
28. Various Consultants, SHPP/GTZ assisted Nepali small hydropower (up to 10MW) study reports at
various levels (about 65 projects), 2001-2006.
29. Small Hydro Engineers Consultants P Ltd, Detailed Project Report (DPR) of 5MW Soldan Small
Hydropower Project, Himachal Pradesh, India, 2001.
30. Small Hydro Engineers Consultants P Ltd, Detailed Project Report (DPR) of 4.5MW Sarbari Small
Hydropower Project, Himachal Pradesh, India, 2001.
31. Entec AG, Switzerland, 240 kW Dewata Tea State Mini Hydropower Scheme Feasibility Study,
West Java, Indonesia, 2000.
32. Entec AG, Switzerland, 585 kW Jegu Village Mini Hydropower Plant Feasibility Study, East Java,
Indonesia, 2000.
33. Son Vu Energy Development Joint Stock Company, 3.2MW Nhap A Hydropower Project Final
Feasibility Report, Hoa Binh, Vietnam, 2005.
34. Hanoi Construction Company, 3MW Sao Va Hydropower Project Feasibility Report, Nghe An
Province, Vietnam, 2005.
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DRAWINGS
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Objectives:
The objective of the project is to establish a market for small hydro power development,
rehabilitation and operation which will in turn facilitate the expansion of rural electrification and
leads to associated economic activities and rural development.
Activities:
1. Strengthening of Policy Frame Work
SHPP provides input to the formulation of hydropower and other related policies, acts and
regulations.
2. Technical and logistic support from desk studies to operation of small hydropower schemes on:
Performance and optimization studies incorporating efficient technologies
Review of projects including financial analysis, hydrological studies, environmental
protection, civil works , metal works, electro-mechanical works, transmission lines, etc.
Preparation of model contracts on civil construction, mechanical works, etc.
Technical supports to under-construction small hydropower projects.
Operation, repair, maintenance and rehabilitation
3. Capacity building of stakeholders
Conducting seminars, workshops and forums for professionals and stakeholders in SHP.
Facilitating Nepali developers to participate in seminars, workshops and forums organized by
others.
4. Facilitating Investment
SHP facilitate on building up of financial set ups of small hydropower projects. It also helps
share relevant information among developers and other stakeholders.
5. Assistance and advice to
SHPP provides assistance and advice to Independent Power Producers (IPPs) on the maximum
use of electricity by increasing load factors and utilizing off-peak hours of isolated plants to
increase revenue streams. It also assist prospectus leases on assessing inventories and
requires repair & maintenance statements of NEA schemes
Approaches:
In order to overcome the entrepreneur's hesitation and / or inability to engage in the small
hydropower sector, the project offers a common platform for public and private stakeholders. The
platform allows them to make each other aware of their specific constraints as well as their mutual
interest in developing a partnership for satisfying the uncovered electricity demand of the rural
areas. In this way, the project seeks to have the barriers to private sector's involvement in the
small hydropower field reduced or eliminated. The projects also works directly with the developers
assisting them to acquire services they require to implement and operate successful projects.
Institutional Framework:
The project has an Advisory Committee which has the representation from Ministry of Water
Resources (MoWR), Department of Electricity (DoED) and German Technical Cooperation (GTZ).
The committee meets, as and when required, to discuss and approve policies and directives for the
execution of plans and programs.
The implementing consultants of Small Hydropower Promotion Project are ENTEC, Switzerland
and Winrock International, Nepal.