DESIGN AND FARICATION OF SPIRAL WIND

TURBINE BLADE

ABSTRACT

A spiral wind turbine gives an inherit advantage of the spiral curves

to provide a gradual change in curvature from straight section to a curved

section. When the spiral blade catches the wind, rotating force is generated due

to the aerodynamic properties caused by Magnus Effect. This type of turbine is

better than normal type more effective, cheaper the construction cost and it can

withstand high wind velocity. it consists of spiral blade which is supported with

the frame and bearings . the shaft from the blade is coupled with an alternator

so the required power can be delivered from the alternator . Spiral Wind turbine

blade which has large blade length with small overall turbine height, that will

operate even for low wind velocity (1.5m/s and above) and generate 100 to150

watts that target for house hold application. the shaft material used in this

turbine is mild steel and blade material used in the turbine is GI sheet. The

prime reason for using GI sheet is the ease of cutting, easy availability, low cost

when compared with fiber glass and also good corrosion resistance.

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 CHAPTER 1

INTRODUCTION

1.1The electricity sector in India

The electricity sector in India had an installed capacity of 214.630 GW as

of February 2013, the world's fifth largest. Captive power plants generate an
additional 31.5 GW. Non Renewable Power Plants constitute 87.55% of the
installed capacity and 12.45% of Renewable Capacity.

The per capita average annual domestic electricity consumption in India in 2009
was 96 kWh in rural areas and 288 kWh in urban areas for those with access to
electricity, in contrast to the worldwide per capita annual average of 2600 kWh
and 6200 kWh in the European Union. India's total domestic, agricultural and
industrial per capita energy consumption estimates vary depending on the
source. Two sources place it between 400 to 700 kWh in 20082009. As of
January 2012, one report found the per capita total consumption in India to be
778 kWh.

India currently suffers from a major shortage of electricity generation capacity,

even though it is the world's fourth largest energy consumer after United States,
China and Russia. The International Energy Agency estimates India needs an
investment of at least $135 billion to provide universal access of electricity to
its population.

The International Energy Agency estimates India will add between 600 GW to
1200 GW of additional new power generation capacity before 2050. This added
new capacity is equivalent to the 740 GW of total power generation capacity of

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European Union (EU-27) in 2005. The technologies and fuel sources India
adopts, as it adds this electricity generation capacity, may make significant
impact to global resource usage and environmental issues.

India's network losses exceeded 32% in 2010 including non-technical losses,

compared to world average of less than 15%. Both technical and non-technical
factors contribute to these losses, but quantifying their proportions is difficult.
But the Government pegs the national T&D losses at around 24% for the year
2011 & has set a target of reducing it to 17.1% by 2017 & to 14.1% by 2022.
Some experts estimate that technical losses are about 15% to 20%, A high
proportion of nontechnical losses are caused by illegal tapping of lines, but
faulty electric meters that underestimate actual consumption also contribute to
reduced payment collection. A case study in Kerala estimated that replacing
faulty meters could reduce distribution losses from 34% to 29%.

Key implementation challenges for India's electricity sector include new project
management and execution, ensuring availability of fuel quantities and
qualities, lack of initiative to develop large coal and natural gas resources
present in India, land acquisition, environmental clearances at state and central
government level, and training of skilled manpower to prevent talent shortages
for operating latest technology plants.

1.2 RENEWABLE ENERGY

Renewable energy in India is a sector that is still in its infancy.

As of December 2011, India had an installed capacity of about 22.4 GW of

renewal technologies-based electricity, about 12% of its total. For context, the

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total installed capacity for electricity in Switzerland was about 18 GW in 2009.
The table below provides the capacity breakdown by various technologies.

As of August 2011, India had deployed renewal energy to provide electricity in

8846 remote villages, installed 4.4 million family biogas plants, 1800
microhydel units and 4.7 million square meters of solar water heating capacity.
India anticipates to add another 3.6 GW of renewal energy installed capacity by
December 2012.

India plans to add about 30 GW of installed electricity generation capacity

based on renewal energy technologies, by 2017.

1.3WIND ENERGY

Wind is a form of solar energy. Winds are caused by the uneven heating of
the atmosphere by the sun, the irregularities of the earth's surface, and rotation
of the earth. Wind flow patterns are modified by the earth's terrain, bodies of
water, and vegetative cover. This wind flow, or motion energy, when
"harvested" by modern wind turbines, can be used to generate electricity.

The terms "wind energy" or "wind power" describe the process by which
the wind is used to generate mechanical power or electricity. Wind turbines
convert the kinetic energy in the wind into mechanical power. This mechanical
power can be used for specific tasks (such as grinding grain or pumping water)
or a generator can convert this mechanical power into electricity to power
homes, businesses, schools, and the like.

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1.4WIND POWER IN INDIA

India has the fifth largest installed wind power capacity in the world. In
2010, wind power accounted for 6% of India's total installed power capacity,
and 1.6% of the country's power output.

The development of wind power in India began in the 1990s by Tamil Nadu
Electric Board near Tuticorin, and has significantly increased in the last few
years. Suzlon is the leading Indian company in wind power, with an installed
generation capacity of 6.2 GW in India. Vestas is another major company active
in India's wind energy initiative.

As December 2011, the installed capacity of wind power in India was 15.9GW,
spread across many states of India. The largest wind power generating state was
Tamil Nadu accounting for 30% of installed capacity, followed in decreasing
order by Maharashtra, Gujarat, Karnataka, and Rajasthan. It is estimated that 6
GW of additional wind power capacity will be installed in India by 2012. In
Tamil Nadu, wind power is mostly harvested in the southern districts such as
Kanyakumari, Tirunelveli and Tuticorin.

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1.5WIND TURBINE

Wind turbines, like aircraft propeller blades, turn in the moving air and
power an electric generator that supplies an electric current. Simply stated, a
wind turbine is the opposite of a fan. Instead of using electricity to make wind,
like a fan, wind turbines use wind to make electricity. The wind turns the
blades, which spin a shaft, which connects to a generator and makes electricity.

WIND TURBINE TYPES

Modern wind turbines fall into two basic groups; the horizontal-
axis variety, like the traditional farm windmills used for pumping water, and
the vertical-axis design, like the eggbeater-style Darrieus model, named after its
French inventor. Most large modern wind turbines are horizontal-axis turbines.

Small wind turbines are generally categorized as:

Horizontal axis wind turbines (HAWT):

In these models the shaft is parallel to the ground. Although they must self-
align with the wind, HAWTs are mechanically simple and require a relatively
small footprint on the ground to mount and secure the tower. The majority of
small and large turbines installed today are HAWTs.

Vertical axis wind turbines (VAWT):

In these models the shaft is perpendicular to the ground. These turbines

typically require a relatively large footprint on the ground to mount and secure
the tower.

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1.5.1SPIRAL WIND TURBINE

Spiral wind turbines have grown in popularity recently especially for

home and urban use. Many spiral wind turbines look like DNA structures, large
drill bits or other spiral designs which catch the wind and produce electricity.

The spiral wind turbine is quieter than bladed turbines because of slower speeds
along the blade tips. Another advantage of the spiral wind turbine design is that
many times slow minimum wind speeds are needed in order to get the device
rotating.

Typically, spiral wind turbines are designed along a vertical axis. Vertical axis
wind turbines are generally gaining popularity for residences and urban settings
because they can be placed lower to the ground and on rooftops.

Spiral wind turbines can be mounted on rooftops, in yards, at airports or other

settings depending upon the exact design and application. They can be tower
mounted or mounted close to the base.

1.5.2ADVANTAGES OF SPIRAL WIND TURBINE:

The advantage of the spiral wind turbine is that it generally can be used in
areas with higher wind speeds where bladed turbines would need to be shut
down for safety reasons.

Another advantage of the spiral wind turbine is bird safety. In recent years,
manufacturers of utility scale horizontal axis bladed wind turbines have come
under fire for killing birds especially in migratory paths.

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With a spiral wind turbine, bird issues have rarely been a concern. Spiral wind
turbines are also less susceptible to problems with crosswinds than bladed
turbines and they require no tail-fan to keep them pointed in the optimal
direction.

ADVANTAGE OF SPIRAL AXIS WIND TURBINE OVER

HORIZONTAL AXIS WIND TURBINE

There are several reasons why we would choose a vertical axis wind turbine
over a horizontal axis windmill.

1. They are mounted lower to the ground making it easy for maintenance if
needed.

2. They start creating electricity at speeds of only 6 mph. And

3. Third, they may be able to be built at locations where taller structures, such
as the horizontal type, can't be.

4. Higher power utilization-- 20% higher than HAWT.

5. Lower noise level only, suitable for your living condition.

6. Safer operation--Spin at slower speeds than horizontal turbines, decreasing

the risk of injuring birds and also decreasing noise level.

1.5.3PROPERTIES OF MATERIALS USED

Blade

The blade material used is galvanized iron sheet of 1mm thickness. Because of
its easy availability & less cost.

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The youngs modulus value for galvanized iron is 70 GPa

The Yield Stress value for galvanized iron is 248 Mpa

The Ultimate Stress value for galvanized iron is 70Mpa

Hollow shaft & frame

The hollow shaft material used is mild steel of 25mm. Because of its easy
availability & less cost.

The frame is also made up of mild steel. Because of its easy availability & less
cost.

The youngs modulus value for mild steel is 200 Gpa

The Yield Stress value for mild steel is 485 Mpa

The Ultimate Stress value for mild steel is 410 Mpa

Fracture Stress

As the reduction in cross sectional area continues, the load bearing capacity of
specimen reduces gradually. At a certain stage cross sectional of specimen is so
small that it cannot sustain the load & hence it breaks. The stress at which the
specimen breaks is known as fracture stress. It is generally less than ultimate
stress for ductile materials.

Hardness

It is the measure of resistance to penetration &abrasion, which is a function of

stress required to produce some specified type of failure. It is generally
expressed as a number.
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 Toughness: The ability of material to absorb energy in the plastic range is
known as toughness. Toughness per unit volume of the material is known as
modulus of toughness.

Poissons ratio

The ratio between lateral strain and longitudinal strain is known as Poissons
ratio. The value for galvanized iron is (0.26 - 0.31)

1.6 SCOPE OF THE PROJECT

To utilize the available wind resources and to reduce the usage of non
renewable energy resources. Wind energy is by far the fastest-growing
renewable energy resource. The wind energy industry so far has been supported
by market incentives backed by government policies fostering sustainable
energy resources.

Large-scale wind facilities approaching the output rating of conventional power

plants, control of the power quality is required to reduce the adverse effects on
their integration into the network. These wind turbines can be used to provide
constant lighting. In most cities, bridges are a faster route for everyday
commute and in need of constant lighting makes this an efficient way to
produce natural energy.

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1.7APPLICATIONS OF WIND ENERGY

Wind-turbine generators have been built a wide range of power outputs from
kilowatt or so to a few thousand kilowatts, machine of low power can generate
sufficient electricity for space heating & cooling & for operating domestic
appliances.

Low power WEC generators have been used for many years for the corrosion
protection of buried metal pipe lines. Application of more powerful turbines up
to about 50kw, are for operating irrigation pumps, Navigational signal. Aero
generators in the intermediate power range, roughly 100 to 25 KW can supply
electricity to isolated populations.

1.8CHARACTERISTICS & SPECIFICATIONS OF WIND TURBINES

Wind Speed

This is very important to the productivity of a windmill. The wind turbine only
generates power with the wind. The wind rotates the axis (horizontal or vertical)
and causes the shaft on the generator to sweep past the magnetic coils creating
an electric current.

Blade Length

This is important because the length of the blade is directly proportional to the
swept area. Larger blades have a greater swept area and thus catch more wind
with each revolution. Because of this, they may also have more torque.

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 Base Height

The height of the base affects the windmill immensely. The higher a windmill
is, the more productive it will be due to the fact that as the altitude increases so
does the winds speed.

Base Design

Some base is stronger than others. Base is important in the construction of the
windmill because not only do they have to support the windmill, but they must
also be subject to their own weight and the drag of the wind. If a weak tower is
subject to these elements, then it will surely collapse. Therefore, the base must
be identical so as to insure a fair comparison.

1.8 REQUIREMENTS FOR PLACING

Site Selection considerations

The power available in the wind increases rapidly with the speed; hence wind
energy conversion machines should be located preferable in areas where the
winds are strong & persistent. The following point should be considered while
selecting site for Wind Energy Conversion System (WECS).

High annual average wind speed

The wind velocity is the critical parameter. The power in the wind Pw, through
a given X section area for a uniform wind Velocity is

Pw = KV3 (K is constant)

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 It is evident, because of the cubic dependence on wind velocity that small
increases in V markedly affect the power in the wind

e.g. doubling V, increases Pw by a factor of 8.

Availability of wind V(t) curve at the proposed site

This important curve determines the maximum energy in the wind and hence is
the principle initially controlling factor in predicting the electrical o/p and hence
revenue return of the WECS machines, it is desirable to have average wind
speed.

Wind structures at the proposed site

Wind especially near the ground is turbulent and gusty, & changes rapidly
indirection and in velocity. This departure from homogeneous flow is
collectively referred to as the structure of the wind.

Altitude of the proposed site

If affects the air density and thus the power in the wind & hence the useful
WECS electric power o/p. The winds tends to have higher velocities at higher
altitudes.

Local Ecology

If the surface is bare rock it may mean lower hub heights hence lower structure
cost, if trees or grass or ventation are present. All of which tends to destructure
the wind.

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 Nearness of site to local center/users

This obvious criterion minimizes transmission line length & hence losses &
costs.

Nature of ground

Ground condition should be such that the foundations for WECs are secured,
ground surface should be stable.

Favorable land cost: Land cost should be favorable as this along with other
sitting costs, enters into the total WECS system cost.

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 CHAPTER2

LITERATURE REVIEW

2.1The Source of Winds

In a macro-meteorological sense, winds are movements of air masses in the
atmosphere mainly originated by temperature differences. The temperature
gradients are due to uneven solar heating. In fact, the equatorial region is more
irradiated than the polar ones. Consequently, the warmer and lighter air of the
equatorial region rises to the outer layers of the atmosphere and moves towards
the poles, being replaced at the lower layers by a return flow of cooler air
coming from the Polar Regions. This air circulation is also affected by the
Coriolis forces associated with the rotation of the Earth. In fact, these forces
deflect the upper flow towards the east and the lower flow towards the west.
Actually, the effects of differential heating dwindle for latitudes greater than
30oN and 30oS, where westerly winds predominate due to the rotation of the
Earth. These large-scale air flows that take place in all the atmosphere
constitute the geostrophic winds.
The lower layer of the atmosphere is known as surface layer and extends to a
height of 100 m. In this layer, winds are delayed by frictional forces and
obstacles altering not only their speed but also their direction. This is the origin
of turbulent flows, which cause wind speed variations over a wide range of
amplitudes and frequencies. Additionally, the presence of seas and large lakes
causes air masses circulation similar in nature to the geostrophic winds. All
these air movements are called local winds.

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2.2The power in the Wind

The power in the wind can be computed by using the concepts of kinetics. The
wind mill works on the principle of converting kinetic energy of the wind to
mechanical energy. The kinetic energy of any particle is equal to one half its
mass times the square of its velocity,

Kinetic Energy = mv2.

Amount of Air passing is given by

m = * AV ..(1)

Where

m = mass of air transferring

A=area swept by the rotating blades of wind mill type generator

= Density of air

V= velocity of air

Substituting this value of the mass in expression of K.E.

= *AV.V2 watts

pw = * AV3 watts .. (2)

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 CHAPTER 3

DESIGN CALCULATION

DESIGN OF SPIRAL AXIS WIND TURBINE BLADE

A wind mill is machine for wind energy conversion. A wind turbine converts
the kinetic energy of the winds motion to mechanical energy transmitted by the
shaft. A generator further converts it to electrical energy. So it is necessary to
keep in mind, while designing the windmills structural part.

ASSUMPTIONS:

-Wind velocity is taken in a range of 8m/s.

-Tip speed ratio: 1.5

LIMITATIONS:

-The GI blade we used will may form rust under different weather
conditions.

-no adequate power obtained due to change in wind velocity.

T - Atmospheric temperature (313K)

P - Atmospheric pressure (N/m2)

R - Gas constant

air - Density of air kg/m3

- The tip speed ratio 1.5

v - Wind velocity in (m/s)

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3.1 DESIGN OF BLADE:

Wind turbine blades have on aerofoil type cross section and a variable pitch.
While designing the size of blade it is must to know the weight and cost of
blades. In the project one blade with vertical shaft are used, it has a height &
width of 1m & 0.6m respectively. The angle of blades is 45 0 folded in corners as
to increase the tip speed ratio. So if Blade moves the wind the other side of the
blade is subjected to wind .which has high performance.

Area of blade=Length*breath
Area=1*0.6=0.6m2

FRONT VIEW TOP VIEW

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1) Density Of Air:

The density of air is given by

P-atmospheric pressure (1.013*105 N/m2)

T- atmospheric temperature(313K)

air = P/RT

= 1.013*105 /287*313

air =1.19 Kg/m3

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2) Power available in the wind:

The available power in the wind Pw:

Pw= (A*Pair*v3) /2

pw= (0.6*1.19*83)/2

pw =182.78 watts

Pt is the power of a wind turbine is given by:

Pt= 0.5*0.589*1.190*0.6*83

Pt =107.6watts

Rotor efficiencies were calculated using the formula:

The efficiency of rotor is given by:

=107.6/182.78

wt =58.9%

59% efficiency is the BEST a conventional wind turbine can do in

extracting power from the wind.

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Turbine rotational speed:

N = (*v/R)*(60/2)

N= (1.5*8/0.3)*(60/2)

N= 383rpm

3.2 DESIGN OF SHAFT

While designing the shaft of blades it should be properly fitted to the blade. The
shaft should be as possible as less in thickness & light in weight for the six
blade, the shaft used is very thin in size are all properly fitted. So no problem of
slipping & fraction is created, it is made up of hollow steel which is having
light weight & less cost. Length of shaft & diameter are 35cm & 2.54cm
respectively. And at the top and bottom ends mild steel of length 1inch each are
respectively are fixed to give strength to the hollow shaft.

Torque calculation

Pt=2NT/60
107.6=2*383*T/60

T=2.68Nm
3.3 DESIGN OF PLUMBER BLOCK

For the smooth operation of Shaft, bearing mechanism is used. To have very
less friction loss the two ends of shaft are pivoted into the same dimension
plumber block. Plumber block are generally provided for supporting the shaft
and smooth operation of shaft. We have used plumber block for the purpose of
easy of maintenance

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3.4 SPECIFICATIONS OF WIND TURBINE

Length of blade : 1m

Width of blade : 0.6m

Hollow shaft : 20mm (diameter)

Plumber block : 2no

blade thickness : 1mm

Frame height : 1.35m

Frame width : 1m

Angle : 45

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 CHAPTER4

FABRICATION

Fabrication is done in the above process

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3.1 FABRICATION

The material is selected on the basis of its property. The material is purchased
for the required dimension. Then the blade is folded using roller machine for
the dimension.

A cutting torch is used to heat cut frame. A stream of oxygen & oxyacetylene is
used.

Arc welding is used to weld the frame. The electrode of 3mm is used to weld.

Then the blade is assembled in the frame using plumber block.

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26
CONCLUSION
Our work and the results obtained so far are very encouraging and reinforce the
conviction that vertical spiral axis wind energy conversion systems are practical
and potentially very contributive to the production of clean renewable
electricity from the wind even under less than ideal sitting conditions. It is
hoped that they may be constructed used high-strength, low- weight materials
for deployment in more developed nations and settings or with very low tech
local materials and local skills in less developed countries. The spiral wind
turbine designed is ideal to be located on top of a home to generate electricity,
powered by wind. The elevated altitude gives it an advantage for more wind
opportunity. With the idea on top of a home, it will power up lights and or
commercial use.

SL NO TURBINE WIND VELOCITY POWER (watts)

SPEED (RPM) (m/s)
1 31 1.1 0.278
2 58.1 1.6 0.86
3 77 1.9 1.44
4 88 2.5 3.28
5 98 3.0 5.67

FUTURE DEVELOPMENTS
The development of effective alternators and dynamos can be used to harness
wind energy from relatively small winds.

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LIST OF MATERIAL AND COST ESTIMATION

NO.OF MATERIAL QUANTITY COST

COMPONENTS (rs)
Sheet metal GI 1 400
frame Mild steel 16 meter 1600
Plumber block Mild steel 2 600
Hollow shaft Mild steel 2 100
Nut and bolt Mild steel 8 75
Other expenses - - 800
TOTAL - - 3075

REFERENCES

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[1]. Andrew Tendai Zhuga, Benson Munyaradzi, and Clement Shonhiwa
Journal of Design of Alternative Energy Systems: A Self-Starting Vertical Axis
Wind Turbine for Stand-Alone Applications

[2]. Alex Kalmikov and Katherine Dykes

Journal of Wind Power Fundamentals

[3]. Satish chandra balineni , siva rama krishna.r , b.sriram

kumar , g.vijay kumar . Theses report of Design of savonius
vertical axis wind turbine

Websites:

1. http://users.aber.ac.uk/iri/WIND/TECH/Wpcourse/
2. http://www.windturbine-analysis.com, January 29, 2004.
3. http://www.wikipedia.com/vawt/turbine.

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