FACULTY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL AND MECHATRONICS

ENGINEERING
BSc. MECHANICAL AND MANUFACTURING ENGINEERING.
POWER PLANTS

DESIGN OF A MICRO-HYDROPOWER PLANT

ABSTRACT
Many rural areas in Kenya have limited access to electricity and due to this the Kenyan
economy has not achieved full potential. Many of these areas have streams and rivers
which can either be seasonal or permanent and are located in hilly and mountainous
regions. Distributors of electricity may have a difficult time planning for power to reach
these regions.
Citizens of these regions always have a hard time getting connected to the outside world
and miss out on many important news and events that could help empower them.

The report describes a proposed construction of a micro hydropower plant in a region

which has a permanent river flowing through a hilly terrain. A feasibility study was done by
approximating the vertical distance available and flow of the water and a conclusion arrived
at shown that there was sufficient quantity of water available for a successful construction
of a micro-hydropower plant.

Contents
ABSTRACT......................................................................................................................................ii
List of figures...................................................................................................................................iii
CHAPTER ONE..............................................................................................................................1
1.1 BACKGROUND........................................................................................................................1
1.2 PROBLEM STATEMENT........................................................................................................2

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1.3 OBJECTIVES............................................................................................................................2
1.3.1 Main objectives........................................................................................................................2
1.3.2 Specific Objectives...................................................................................................................2
1.4 JUSTIFICATION......................................................................................................................2
LITERATURE REVIEW................................................................................................................3
2.1 HYDROPOWER HISTORY.....................................................................................................3
2.2 PREVIOUS WORKS DONE.....................................................................................................4
CHAPTER THREE.........................................................................................................................6
3.1 DESIGN OF THE PLANT........................................................................................................6
3.2 Construction...............................................................................................................................6
3.3 DESIGN ANALYSIS.................................................................................................................7
4.2 EXPECTED RESULTS.............................................................................................................8
BUDGET...........................................................................................................................................9
REFERENCES...............................................................................................................................10

List of figures
Figure 2.1 micro hydropower diagrams……………………………………….5

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 CHAPTER ONE

1.1 BACKGROUND
A hydropower plant generates electricity by using the motion of moving water to turn a
turbine connected to a generator which in turn generates power. The cost of hydroelectricity
is relatively low, making it a competitive source of renewable electricity.

In Nandi County many people lack access to electricity because of the terrain in which they
are located which presents a challenge to distributors of electricity from ensuring the people
in these regions are supplied with electricity. A micro hydropower plant would ensure
power source is added to the power grid and the community as a whole benefit. Homes
could be supplied with electricity and business centers established therefore the standards
of living would improve for the residents.

A village called Lemook in particular has lacked electricity for a long period of time
because of the challenges aforementioned. Due to this it has not progressed economically.
The proposed power plant design would help achieve prosperity.

The village is located in a hilly terrain with a river flowing in between. The direction of
flow is perfect for the proposed design. With consideration given to the head of water and
the quantity of water flowing in the river. The river is permanent therefore the power plant
will continuously produce electricity for a foreseeable future.

A lot of effort has been made to ensure these households are supplied with electricity. Some
efforts made include installing solar panels in each household. This proved to be
unsuccessful because of the high cost of purchasing the solar panels compared with the low
living standards of the residents. Another challenge of solar panels as a source of energy
was that too little radiation was absorbed by the panels because of the many trees in the
area which blocked direct sunlight. Power transmitted was found to be too little and could
not satisfy the power requirements of the residents.

The hydropower plants are advantageous in that it is an efficient energy source, it is a

reliable electricity source, no reservoir is required, it is a cost-effective energy solution and
it can be integrated with the local power grid.

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1.2 PROBLEM STATEMENT
Electricity is an important aspect of our day to day lives. Residents of Lemook in Nandi
County have for a long time been in the dark. Most of them have been using lanterns and
kerosene to power the lanterns which in the long run takes a huge amount of their income
which could have been otherwise have been spent somewhere else had there been a cheaper
form of electricity at their disposal.

Some residents use solar powered devices known as D-lights to power their homes. These
devices are unreliable and their durability is not more than a year. Another disadvantage of
this form of lighting is that days of insufficient sunlight means there will little or no light to
power their homes. Insecurity may rise in these situations.

My proposed project will help solve the problems aforementioned.

1.3 OBJECTIVES
1.3.1 Main objectives
To design a micro hydropower power plant to power a village and add power source to the
power grid.

1.3.2 Specific Objectives

(i) To determine and analyze the power plant to ensure it is functional.

(ii) To determine the overall cost of setting up the power plant.

(iii) To ensure maximum theoretical power output of the power plant.

1.4 JUSTIFICATION
It is clear that the village is in dire need of electricity and my proposed power plant design
will help achieve this. All the requirements for setting up the power plant are met and it is a
feasible project considering all factors.

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 CHAPTER TWO

LITERATURE REVIEW
2.1 HYDROPOWER HISTORY
By using water for power generation, people have worked with nature to achieve a better
lifestyle. The mechanical power of falling water is an age-old tool. As early as the 1700's,
human beings recognized the advantages of mechanical hydropower and used it extensively
for milling and pumping. By the early 1900's, hydroelectric power in a country such as
America accounted for more than 40 percent of supply of electricity. In the West and
Pacific Northwest, hydropower provided about 75 percent of all the electricity consumed in
the 1940's. With the increase in development of other forms of electric power generation,
hydropower’s percentage has slowly declined to about 10 percent. However, many
activities today still depend on hydropower.

Governments became involved in hydropower production because of its commitment to

water resource management in the arid West. The waterfalls of the Reclamation dams
make them significant producers of electricity. Hydroelectric power generation has long
been an integral part of Reclamation=s operations while it is actually a byproduct of water
development. In the early days, newly created projects lacked many of the modern
conveniences, one of these being electrical power. This made it desirable to take advantage
of the potential power source in water.

Powerplants were installed at the dam sites to carry on construction camp activities.
Hydropower was put to work lifting, moving and processing materials to build the dams
and dig canals. Powerplants ran sawmills, concrete plants, cableways, giant shovels, and
draglines. Night operations were possible because of the lights fed by hydroelectric power.
When construction was complete, hydropower drove pumps that provided drainage or
conveyed water to lands at higher elevations than could be served by gravity-flow canals.

Surplus power was sold to existing power distribution systems in the area. Local industries,
towns, and farm consumers benefited from the low-cost electricity. Much of the
construction and operating costs of dams and related facilities were paid for by this sale of

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surplus power, rather than by the water users alone. This proved to be a great savings to
irrigators struggling to survive in the West.

Small hydroelectric generators, installed prior to construction, provided energy for

construction and for equipment to lift stone blocks into place. Surplus power was sold to
the community, and citizens were quick to support expansion of the dam’s hydroelectric
capacity.

Power development, a byproduct of water development, had a tremendous impact on the

area’s economy and living conditions. Power was sold to farms, cities, and industries.
Wells pumped by electricity meant more irrigated land for agriculture, and pumping also
lowered water tables in those areas with waterlogging and alkaline soil problems. In
addition, Reclamation supplied all of the residential and commercial power needs of
Phoenix. Cheap hydropower, in abundant supply, attracted industrial development as well.
A private company was able to build a large smelter and mill nearby to process low-grade
copper ore, using hydroelectric power.

2.2 PREVIOUS WORKS DONE

According to S.U. Patel, Prashant.N. Pakale, increasing demand of power can be efficiently
and ecologically fulfilled by the use of micro hydel power generation system, as human
civilization can be seen near water reservoirs and there increasing power demand due to
population growth can be fulfilled by this ecologically renewable hydel power project
method [3]. Basic principle in this system is energy generation from flowing water, even if
it is low in pressure. Force produced on blades of turbines due to direction of water diverted
on turbines. This process in turn moves the generator in circular motion to produce
electricity. The basic objective of this research topic is to study outcome, after
introduction of cross movement of water stream in turbines installed in micro level
hydroelectric plant [MHP] for power generation.

One literature review done by Department of Electrical and electronics, Karunya

University, Coimbatore by professor Prawin Angel Michael and, C.P. Tawahar: Design of
15 kW Micro Hydro Power Plant for Rural Electrification at Valara. This topic has been
taken for rural electrification of Valara village in Idukki, India. In Valara around 120
families reside without the facility of electric supply, as there is absence of grid connected

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distribution network. This project was a pilot prototype to do research on the economics
involved and

techniques which can be implemented with respect to hydro projects as there was water
available at current site and water being a free resource can be utilized for low-cost micro
scale hydro project and accordingly suitable electro mechanical components can be studied
and used. [4] For this 15kW micro scale hydel electric system was designed, installed and
tested in rural distribution type of conditions. This plant is not only fulfilling the power
needs of tribal families but also providing a source of livelihood to them by the means of
maintenance and daily working of the plant. This is also developing skills in tribal by
means of practical knowledge of hydro power systems. [4]

Diagrams of micro hydropower designs;

Figure 2.1; micro hydroelectric power water flow system.

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 CHAPTER THREE

3.1 DESIGN OF THE PLANT

The proposed micro-hydropower design is to produce approximately 80-100KW of
electricity using a water flow. Micro hydropower plants have the following components;

1. Water conveyance- it is a channel/pipeline which delivers water from a point

higher up the hillside downhill which is used to drive the turbine.
2. Turbine; it transforms the energy of flowing water into rotational energy.
3. Generator; it transforms the rotational energy into electricity.
4. Regulator; it is a device which controls the generator.
5. Wiring; it delivers the electricity.

3.2 construction
Micro hydropower systems are made up of a number of components. An intake diverts
water from the river. An intake structure such as a catch box is required to screen out
floating debris and fish, using an array of bars to keep out large objects. Intake should also
have a gate which would allow the system to be dewatered for inspection and maintenance.

The intake is then brought through a canal and then a forebay. The forebay is used for
sediment holding. At the bottom of the system the water is tunneled though a penstock to
the powerhouse building containing a turbine. The penstock builds up pressure from the
water that has travelled downwards.

At the turbine, a controlling valve is installed to regulate the flow and speed of the turbine.
The turbine converts the flow and pressure of the water to mechanical energy. The water
emerging from the turbine returns to the natural watercourse along a tailrace channel [1].

The turbine turns a generator, which is then connected to electrical loads, which then
powers homes of Lemook village. It may also be connected to the power grid.

Impulse turbines are used in my proposed design. The turbines rely on the velocity of water
to move the turbine wheel, which is called the runner. Common type of impulse turbine
used is the Pelton wheel which uses the concept of jet force to create energy [2]. Water is
funneled into a pressurized pipeline with a narrow nozzle at one end. The water sprays out
of the nozzle in a jet striking the double-cupped buckets attached to the wheel.

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The impact of the jet spray on the curved buckets creates a force that rotates the wheel at
high efficiency rates. Pelton wheel turbines operate best under high-head conditions and
therefore fits my proposed design.

3.3 DESIGN ANALYSIS

The power generated by the hydro power plant is calculated from the formula below;

P=Q×Hnet×g×Ƞ

Where Q= Mass flow rate of water

Hnet= the net head

=Hgross×0.9

g= the gravitational constant, which is 9.81 m/s2

Ƞ=product of the component’s efficiencies

= Ƞturbine ×Ƞdrive×Ƞgenerator

The approximated head, Hgross= 7m

Therefore Hnet=7×0.9=6.3m

Flow rate of the water in Kg/s = 2000

For a typical small hydro system, the turbine efficiency would be 85%, drive efficiency
95% and the generator efficiency 93%, so the overall system efficiency would be:

Ƞ=0.85×0.95×0.93= 0.750975

Therefore, hydropower Power:

Power(W)=2000×9.81×0.750975×6.3

=92,825.016W= 92.825KW

The power generated can be maximized by keeping the inlet clear of debris which will
maintain a maximum system head.

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 CHAPTER FOUR
CONCLUSION AND EXPECTED RESULTS
4.1 CONCLUSION
Micro hydropower plants can be an efficient and reliable source of power to the villagers in
Lemook as illustrated from the design criteria. The availability of water flowing at an
increased speed, the terrain and the sufficient head make my proposed design viable. The
society as a whole will benefit from the project and many more villages with such
advantages will follow suit in construction of small-scale hydropower plants.

It is cheaper than most power plants producing the same power and is easy to install,
maintain and repair. Components for construction are also locally available. Due to non-
emission, it is a preferred source of power for a foreseeable future.

4.2 EXPECTED RESULTS

The power plant is expected to provide sufficient power to the residents. It is also expected
to function effectively and efficiently for long periods of time. The plant is also expected to
be easy to install and maintain.

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BUDGET
Serial no. Work item AMOUNT
1. Turbine and generator 6,123,000/=
2. Penstock 36,900/=
3. Steel penstock 2,795,400/=
4. Powerhouse construction materials 961,500/=
5. Distribution lines 6,760,500/=
6. Intake weir (excavation, concrete, gabion) 1,825.600/=
7. Intake and de-silting basin 660,300/=
8. Transformer and switchgears 1,047,000/=
9. Tailrace 64,900/=
10. Headrace and spillway channel 2,296,100/=
11. Gate and trash racks 120,000/=
12. Engineering fee 4,251,100/=
13. miscellaneous 1,764,600/=
GRAND TOTAL 28,946,900/=

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REFERENCES
1. “How a micro hydro system works”, U.S. DOE. Retrieved 28 November 2010.
2. www.energy.gov
3. S.U. Patel, Prashant.N. Pakale “Study on power generation by using cross flow
water turbine in micro hydro power plant” International Journal of Research in
Engineering and Technology, eISSN: 2319-1163 | pISSN: 2321-7308
4. Prawin Angel Michael, C.P. Jawahar. "Design of 15 Kw Micro Hydro
Power Plant for Rural Electrification at Valara", Energy Procedia, 2017

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