Hydropower Device

Fluid Mechanics: MCEN 3021 26 October 2011

By: Jesse Brewer Jason Johnson Justin Robbins

Abstract
The objective of the Hydropower Laboratory is to implement a hydropower device capable of generating between 0.005 0.01 horse power. An actual value of power to be generated will be given to design teams by the instructor on the day of device demonstrations. Generated power will be measured by recording the time at which a given weight is lifted through a distance. A water wheel was designed to generate power from energy stored in the potential head of a reservoir. Cupped paddles were implemented to improve the efficiency of the water wheel along with a gear reduction and chain system to effectively lift the given weight. The water wheel and gear mounts were designed in SolidWorks and obtained via a 3D printer.

I.

Introduction

Hydropower contributes one-fifth of the worlds power generation and provides the majority of [power] supply in 55 countries. For several countries, hydropower is the only domestic energy resource (Kaygusuz 2009). This laboratory is purposed to demonstrate ideas for converting turbine power to mechanical movement while maximizing the efficiency of a hydropower device. Turbine power is defined as power generated by any of various types of machine in which the kinetic energy of a moving fluid is converted into mechanical energy by causing a bladed rotor to rotate. The moving fluid may be water, steam, air, or combustion products of a fuel (Dictionary.com 2009). The hydropower device design and implementation must submit to the following rules provided by the instructor: 1. Submit paper design to instructor per syllabus schedule. 2. No means of storing mechanical energy in the device or take-up line prior to its operation by water will be allowed. Teams must use existing hardware. 3. The device may use shaft gears, pulleys, or other mechanisms attached to the mounting board to convert turbine power to mechanical movement. However, no liquid lubricants or greases may be used unless they are contained in a sealed enclosure. 4. No electrical items may be a part of a device. 5. Your device must be attached to the provided mounting board. 6. No part of the device may protrude from the back of the mounting board. Team members may not hold any part of the device when in operation. 7. The turbine shaft can be in any orientation on the mounting board. 8. Each team will be allowed 15 minutes for set-up time before competition begins. 9. Team will get 2 chances - alternating between other teams if more than one team. 10. General questions concerning rule interpretations are to be submitted to the instructor. Questions and answers are then public information to all teams. If a team wants clarification on the appropriateness of a proposed solution, it may seek private consultation with the instructor. The design of our hydropower device will efficiently convert stored energy in the potential head of a reservoir to a power output between 0.005 0.01 horse power (hp).

II.

Planning

The hydro flow device consists of three main design aspects: the water wheel, mounting chassis, and a gear reduction system. All main design aspects were designed in collaboration of team members with the use of SolidWorks. A chain and sprockets system was selected as an effective means of gear reduction and individual parts were obtained from a local bicycle shop. The water wheel and mounting plates that connect sprockets to the main shafts were obtained via a 3D printer. The sprocket mounting plates were designed to be interchangeable with various sized sprockets to allow for later revision. The mounting chassis was constructed from in. square tubing to provide a rigid frame to be fastened to a metal grate which the device rests on. A gate valve and nozzle were obtained to adjust the flow rate and/or velocity of the water prior to contact with the hydropower device.

III.

Design

A systematic approach was conducted to determine the power that could be generated from a generalized and efficient water wheel. The water wheel will be developed and designed according to the conclusions of the procedure. The procedure is as follows: Step 1. Convert the recorded time at which a weight is lifted through a distance to horse power (Eq. 1). The results were used to generate a graph of power versus the lift velocity of a one kg weight (Fig. 1). [Eq. 1] Figure 1. Graphical representation of output power as a function of the velocity of a one kg weight in the photo gate.

Power vs. Velocity

0.014 0.012 0.01 Power (hp) 0.008 0.006 0.004 0.002 0 0 0.5 1 1.5 2 Velocity (ft/s) 2.5 3 3.5 Power = 0.004*velocity

The graph was used to determine the range of the weights velocities, in ft/s, (min 1.25, max 2.5) necessary to indicate a power output between 0.005 0.01 hp. Step 2. Convert the weights velocity, or tangential velocity, the pulley that reels the weights attached line in (Eq. 2). , to rotations per second, , of

[Eq. 2] The range (min 2.38, max 4.77), in rotations per second, of this pulley was determined by using a pulley diameter of 2 in. and plugging in the minimum and maximum tangential velocities determined in step 1. Step 3. The volumetric flow rate of water, , and the velocity of the water, to the hydropower device were determined (Eq.3). , , to be provided

where A is the area of the pipe. [Eq. 3]

The value of , 3.89 gallons per minute, was obtained via a volumetric flow rate meter and, using a pipe diameter, , of 0.707 in., was calculated to be 3.179 ft/s. Step 4. The Reynolds number, , was calculated (Eq. 4) and the friction factor, , of the PVC pipe supplying water to the hydropower device was determined.

,
where

[Eq. 4] .

is the kinematic viscosity of water at 60

The value of was calculated to be 15,479 and a friction factor of 0.0257 was determined using the Moody Chart with this Reynolds number and a relative roughness of zero (smooth pipe) (Fig. 2). Figure 2. Friction factor as a function of Reynolds number and relative roughness for round pipes.

Source: Native Dynamics 2010

Step 5. Major head losses, (Eq. 5), of the PVC supply pipe and minor head losses, , of the volumetric flow rate meter and electronic valve between the reservoir and the hydropower device were calculated. The total head loss was then calculated/determined from the accumulated data (Eq.6).

,
where is the length of the pipe and

[Eq. 5] is the acceleration due to gravity. is the total head loss. [Eq. 6]

, where

Major head loss, due to friction in the PVC supply pipe, was found to be 0.89 ft. using Eq. 5 and the value of determined in Step 4. Minor losses, due to friction in the volumetric flow rate meter and electronic valve, were determined from manufacturers specs (Fig. 3 and Fig. 4). The head loss value from the volumetric flow rate meter was estimated visually (Fig. 3) and the head

loss value from the electronic valve was extrapolated from graphical data (Fig. 4). The minor head losses for the flow rate meter and electronic valve were determined to be 4.61 ft. and 5.58 ft., respectively. Thus, the equivalent head supplied to the hydropower device is 1.92 ft. (Eq. 7).

, where

= 13 ft. (initial head without losses) [Eq. 7]

Figure 3. Pressure drop curves for a SeaMetrics SPX-075 flow rate meter. The x indicates a 3.89 GPM flow rate corresponding to a pressure drop of 2 psi (4.61 ft.).

Source: Promag Enviro Systems 2010

Figure 4. Graphical representation of head loss due to an Orbit " FPT auto inline valve without flow control.

Head Loss From Valve

40 35 Head Loss (ft) 30 25 20 15 10 5 0 0 5 10 15 20 25 30 35 Flow Rate (gpm) Source: Data from Orbit Irrigation Products,
Inc 2011 curve fit using Microsoft Excel regression

y = 0.0357x2 - 0.3159x + 6.2637 R = 0.9936

Equivalent head is the pressure at the bottom of the pipe when water is actually flowing to the hydropower device, and will always be less than the initial head due to energy losses within the pipe (Canyon Industries, Inc 2011). Step 6. Power supplied to the hydropower device was calculated. Equivalent head and design flow (volumetric flow rate) is used to determine hydro system components and power output

(Eq. 8) (Canyon Industries, Inc 2011). This fact can easily be acknowledged by applying the definitions of static and dynamic pressures. Static pressure is the pressure at the bottom of the supply pipe before the water begins to flow and dynamic pressure is the pressure at the bottom of the pipe once water is flowing. Dynamic pressure will always be less than static pressure because energy is lost once water begins to flow. Dynamic pressure accounts for the pressure (or head) loss and is directly proportional to the equivalent head, whereas static pressure is simply the pressure before flow begins. Thus, static pressure head can be used to approximate power availability and determine general feasibility, but dynamic pressure head (equivalent head) must be used to calculate the actual power available (Oregon Department of Energy 2011). , where is the specific weight of water at 60 . [Eq. 8]

The power supplied to the hydropower device via pressure head was calculated to be 0.00189 hp using the known volumetric flow rate and accurately determined equivalent head (Step 5).

References
Canyon Industries, Inc. Guide to Hydropower. 2011. http://www.canyonhydro.com/guide/HydroGuide11.html (accessed November 01, 2011). Dictionary.com. "Turbine." Collins English Dictionary - Complete and Unabridged 10th Edition. 2009. http://dictionary.reference.com/browse/turbine (accessed November 01, 2011). Kaygusuz, K. "The Role of Hydropower for Sustainable Energy Development." Energy Sources Part B: Economics, Planning & Policy 4, no. 4, 2009: 365-376. Native Dynamics. Knowledge Base. 2010. http://knowledgebase.nativedynamics.com.au/getArticle?article=010004&topic=1 (accessed October 20, 2011). Orbit Irrigation Products, Inc. Products. 2011. http://www.orbitonline.com/search/?searchbox=valve&.x=0&.y=0 (accessed November 01, 2011). Oregon Department of Energy. Micro Hydroelectric Systems. August 05, 2011. http://www.oregon.gov/ENERGY/RENEW/Hydro/Hydro_index.shtml (accessed November 01, 2011). Promac Enviro Systems. Low Flow Meter, chemical resistant, SeaMetrics, #SPX. 2010. http://www.promagenviro.ca/products/low-flow-meter-chemical-resistant-seametrics-spx (accessed November 01, 2011).

4. Design Describe the engineering specifications and targets; critically evaluate existing benchmarks and specifically identify the gaps which the project is intended to fill; show how the concepts evolved and were evaluated; describe and justify the formation of the final product; describe the product synthesis; demonstrate the analyses used for product evaluation; show the details of analysis, experiment or field test results. The content may include the following topics if they apply to the project. a. Design specifications development b. Competitive benchmarks c. Design concept development d. Concepts evaluation e. Product design f. Product evaluation 5. Impact Statement State the potential impact of the designed product to environment and society as a whole, and comment on any potential safety-related issues in the use of the product. Explicit statements to each need to be made here, even if there are no environmental, societal or safety concerns. 6. Conclusions Use evidence to claim major accomplishments. Demonstrate that the final product satisfies the engineering specifications. 7. Recommendations Provide recommendations based on the design work. 8. References Provide a complete list of literature used in completing the design (all must be reverenced in the text). 9. Appendices Include programming, detail drawings, assembly drawings, and product development files.