Republic of the Philippines

CENTRAL MINDANAO UNIVERSITY

Musuan, Maramag, Bukidnon

DEVELOPMENT AND PERFORMANCE EVALUATION OF A VIABLE

PROPELLER FOR MICRO-HYDROELECTRIC POWER GENERATION

TAGANAS, QUEENE FAYETH V.

UNDERGRADUATE THESIS PROPOSAL SUBMITTED TO THE FACULTY

OF THE DEPARTMENT OF MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING, CENTRAL MINDANAO UNIVERSITY,
IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE

BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING

DECEMBER 2023
 Republic of the Philippines
CENTRAL MINDANAO UNIVERSITY
Musuan, Maramag, Bukidnon

TABLE OF CONTENTS

PAGE

CHAPTER

I. INTRODUCTION 1

1.1 Background of the Study 1

1.2 Statement of the Problem 2

1.3 Objectives 2

1.4 Significance of the Study 3

1.5 Scope and Limitation 3

1.6 Time and Place of the Study 4

II. REVIEW OF RELATED LITERATURE 5

2.1 Propeller Configuration 5

2.2 Software Vision 5

2.3 Composite Materials 6

2.4 _____________________ 7

2.5 _____________________ 8

III.METHODOLOGY

3.1 Procedural Flow 22

3.2 Preliminary Data Gathering 23

3.3 Design Calculation and Dimensions 23

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CENTRAL MINDANAO UNIVERSITY
Musuan, Maramag, Bukidnon

3.4 Machine’s Materials and Specifications 47

3.5 CAD Modelling 53

3.6 Components Fabrication and Assembly 54

3.7 Machine Installation 59

3.8 Testing and Data Gathering 59

IV. REFERENCES 58

V. BILL OF MATERIALS AND FABRICATION COST 61

VI. GANTT CHART

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Musuan, Maramag, Bukidnon

Chapter 1

INTRODUCTION

1.1 Background of the Study

Using water from a stream or river to generate energy is essentially pollution

free and renewable. The energy in falling water is typically lost as heat due to

turbulence, which raises the water's temperature by 0.25 degrees for every 100

meters lowered. A portion of this energy is converted to electricity by a water turbine

and generator, and the electricity ultimately finds its way back into the environment

as heat.

The word "micro" describes a generating system that produces a few

kilowatts of electricity, often less than 10k W. More significantly, though, the phrase

also describes principles found in the design that are distinct from those found in

bigger systems.

Turbines convert hydraulic energy of water into mechanical energy which is

further converted into electrical energy. This energy obtained is known as hydro-

electric power which is one of the cheapest forms of energy generation. The

amount of production of electricity from a hydropower installation depends on the

quantity of water passing through a turbine and head of water available. The

greater the flow and head the more electricity is produced. The role of hydro plants

becomes more and more important in today’s global renewable energy. Principal
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components consist of a spiral casing, stay vanes, wicket gates/guide vanes,

runner and a draft tube. (Parashar et al., 2017)

The three most crucial needs are affordability, dependability, and safety. The

micro hydro system needs to be simple to maintain and repair, and it needs to be

just as safe and dependable as a large system. The design needs to be suitable for

one-off production in a small workshop. Since ownership is often private, the cost—

which consists nearly entirely of initial capital—needs to be kept to a minimum. A

well-designed micro hydro system will be more affordable and practical than other

renewable energy sources, a diesel-powered generator, or the like if a suitable

water supply is available. national grid, even in cases when the closest electricity

lines are just a few kilometers away.

The system has to be simple in order to meet these needs. This implies that

non-specialists may design, construct, and maintain the structures and equipment

because there are fewer moving parts and reduced maintenance requirements.

This ought to guarantee a little expense. Using easily accessible equipment, such

as centrifugal pumps employed backwards as turbines, can lower costs. The

system's simplicity could come at the expense of its effectiveness; however

effectiveness is frequently subordinated to the need for cheap costs overall.

1.2 Statement of the Problem

Hydroelectric power generation has been acknowledged as a sustainable

energy source, yet prior propeller designs used in these systems have been shown
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to be inefficient due to severe flaws in materials and design. These designs'

shortcomings have led to less-than-ideal performance, which makes it more difficult

to effectively use hydroelectric power. Residents in distant or off-grid locations,

especially in Mindanao, have significant challenges in obtaining dependable and

sustainable energy access due to the ongoing limits of current technologies. In

order to increase the efficiency of hydroelectric power generation and remove the

obstacles that these populations in these locations have in obtaining electricity, this

study aims to solve these important challenges by methodically creating and

improving upon current propeller designs.

1.3 Objectives

The general objective of this study is to address the problem of a low head

micro hydroelectric power generation by;

1. designing model propellers that can generate more power than the previous

ones

2. choosing a reasonable propeller material and price

3. simulate generated designs of propeller and compare each performance

1.4 Significance of the Study

This study's potential to completely change how people obtain electricity in

isolated or off-grid locations—particularly in the Mindanao region—underlines how

important it is. Enhancing the technology of hydroelectric power generation through

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the creation of more effective propeller designs has the potential to alleviate the

ongoing problems encountered by areas who do not have access to dependable

electricity. The research intends to improve the general well-being and economic

growth of the local population in these locations by improving the current

technologies. In addition, the search for sustainable energy solutions promotes a

more ecologically responsible method of generating power by reducing

dependency on non-renewable resources.

The study's focus on Mindanao is indicative of its dedication to focused

regional development, which seeks to strengthen communities and have long-

lasting beneficial effects on their socioeconomic circumstances. In conclusion, the

relevance of this research goes beyond the confines of academia, with the goal of

really improving people's lives in isolated areas by offering a more efficient,

dependable and sustainable energy source.

1.5 Scope and Limitations

In order to improve hydroelectric power generation in Northern Mindanao's

rural locations, this research uses software simulations to optimize propeller

designs. The study covers design alterations and material analysis, however it is

restricted to virtual design without practical manufacture. Field testing is limited by

time and money, and it might not cover all of Mindanao's isolated regions. Although

systemic issues are recognized, the focus is mostly on technological elements.

Weather and other outside variables might affect practical applicability.

Notwithstanding its limits, the study aims to offer significant perspectives for
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promoting hydroelectric power generation by means of virtual design and

simulation techniques.

1.6 Time and Place of the Study

The study's location is primarily in a virtual environment, where design

modifications and simulations take place using relevant software tools.

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CENTRAL MINDANAO UNIVERSITY
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Chapter 2

REVIEW OF RELATED LITERATURE

Propeller Configuration

The paper delves into the numerical simulation of an axial flow hydraulic

propeller turbine runner, focusing on the effect of the flow direction angle at the inlet

boundary on its performance. Employing ANSYS CFX, the study systematically

varies the flow direction angle from 60° to 80° in 2° increments. Results

demonstrate a direct proportional increase in both torque and power output with

higher flow direction angles. Notably, the paper suggests the potential use of this

angle adjustment as an alternative to guiding vanes for tuning turbine load. While

outlining the study's limitations, the paper sets the stage for future research,

offering practical insights for optimizing the efficiency of axial flow hydraulic

propeller turbine runners. (Maulana et al., 2015)

A highly efficient and compact hydraulic propeller turbine with low head

geometry may be created using an optimized design process that has been

established. The primary geometrical parameters of the turbine preliminary design

are related to the basic design parameters through the use of statistical correlations

and fundamental turbomachinery mean-line equations. An automated aerodynamic

single point optimization process based on a genetic algorithm that creates and

updates a large database of turbine shapes is initiated using the initial geometry

that is produced. The method builds the matching database of performance using a
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three-dimensional (3D) Reynolds averaged Navier-Stokes (RANS) solver. To

expedite design optimization, a meta-model—such as an artificial neural network

(ANN)—is employed. The process has been used on a real-world prototype of a

unique, simpler hydraulic propeller turbine designed for extremely low heads. Once

diameter, mass flow rate, and rotational speed are assigned, the chosen design

optimization technique may alter the turbine blade and vane geometries to

automatically achieve the intended net head and the maximum for the total to total

internal efficiency. (Barsi et al., 2021)

In order to highlight the difficulties in simulating transient operations, this

study focuses on modeling the operation of a 10 MW Kaplan prototype turbine at

various operating points. The study investigates ways to make models less

complicated and examines how different aspects affect numerical outcomes. The

numerical simulations demonstrate good predictions for mean torque and pressure

values, and they are tested against experimental results. Nevertheless, differences

are seen in the amplitudes of pressure variations under part-load circumstances,

underscoring the difficulties in precisely simulating full-scale turbine behavior

computationally. (Lovanel et al., 2022)

Software Vision

In the realm of propeller turbine blade and runner modeling, limited literature,

particularly utilizing Autodesk Inventor, exists. A published paper titled "CAD

Modelling of Axial Turbine Blade using Autodesk Inventor" explores this domain,

highlighting a complex methodology necessitating a repetitive process for each new

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axial propeller turbine design. However, a recent enhancement in Autodesk

Inventor—the Equation Curve tool—simplifies the 3D modeling task by facilitating

spline line sketching in 2D or 3D space. The tool relies on codes generated from

two sources: NACA report no. 460 and Milos's proposed modeling methodology.

The NACA report elucidates the creation of the NACA 4 Digit Series, providing

equations for 2D plane sketching, while Milos's method transforms these into 3D

space. The resulting codes are input into the 3D Equation Curve tool, generating

lines for each cylindrical surface section of the blade. The subsequent steps involve

using loft, stitch, and pattern commands to form the solid model, followed by

simulation in ANSYS Fluent, yielding a hydraulic efficiency of 85%. This innovative

approach streamlines the intricate process of propeller turbine modeling,

showcasing the practical application of Autodesk Inventor's evolving capabilities.

(Djodikusumo et al., 2016)

The 3D model of cylinder head and cooling water channel is built in the Pro /

E software, the channel model is trimmed and divided to get the grid correspond

with the computational requirements in the ICEM CFD, the fluid solving parameters

and boundary conditions and other related information is set in the CFX software,

the solid domain and the coupling parameter is set in the ANSYS MFX module,

then the temperature field of cylinder head and waterways, wall convection heat

transfer coefficient and other information is got. The overall design’s rationality can

be known from the temperature field, but between two outlets of the cylinder head,

the highest temperature of the cooling water is 363K, it can be known from the flow

of the cooling water that this part is not easy to be cooled, further improvement of
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the cylinder head structure should be made to improve the cooling effect of cylinder

head. (Fei 2011)

This thesis focuses on enhancing the product development process for

marine propellers by introducing an improved propeller design code, OpenPVLSW.

Developed from the Open propeller vortex lattice lifting line code (OpenPVL),

OpenPVLSW incorporates design iteration through SolidWorks, CosmosFloWorks

for thrust simulation, and CosmosWorks for strength assessment. Using a

parametric design technique in MATLAB, a single propeller geometry generator

facilitates the creation of a propeller blade geometry file for SolidWorks. This study

aims to extend the utility of the original OpenPVL code to encompass not only

propeller design but also thrust simulation and strength checks using SolidWorks

tools. Through a case study involving an AUV propeller, the OpenPVLSW code

demonstrates its efficacy in providing accurate propeller geometry and reliable

thrust simulation results, showcasing its applicability in achieving flexibility and

speed in marine propeller product development. (Xueyin 2010)

Composite Material

This study explores the challenges of utilizing tidal currents for power

generation, emphasizing the need for robust turbine blades due to the high density

of seawater. The research focuses on determining the mechanical properties of a

tidal turbine, specifically evaluating the feasibility of using composite materials for

the turbine blade. The study includes FEM analysis of various materials, such as

rolled steel, aluminum bronze, and Glass Fiber Reinforced Plastic (GFRP) for blade
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construction. Two models, one mimicking a propeller blade and the other a wind

turbine blade, were analyzed. While GFRP for the propeller-type blade showed

insufficient rigidity and shear strength, the wind turbine-type blade demonstrated

workability. However, composite materials' durability in vibratory cavitation erosion

tests proved inferior to metals, suggesting the need for careful consideration in

material selection for tidal turbine applications. (Uzawa et al., 2018)

Composite materials have offered some improvements on the performance

of hydrodynamic and structures of marine constructions. In order to lessen the load

and stress distribution on the structure, the high strength to weight and stiffness to

weight ratios may be customized by taking use of the fiber orientation. The goal of

the research is to compare the rigid and flexible models used for the simulation

analysis of the propeller performance in order to fully explore the performance of

the developed glass fiber reinforce plastics (GFRP) B-series propeller for traditional

purse seine boats in the North Coast of Central Java. There includes discussion of

the two propeller types' thrust force, torque moment, and efficiency. (Windyandari et

al., 2019)
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Shukla, R. S., & Parashar, Dr. C. (2017). Design of Propeller Turbine for Micro Hydro

Power Station Using CFD. Retrieved November 16, 2023, from http://ijses.com/wp-

content/uploads/2017/07/201-IJSES-V1N7.pdf

Q. Maulana B.S., A. Susatyo, M. Fathul H. and Suherman, "Numerical simulation of

the effect of flow direction angle at inlet boundary condition on flow characteristics

and performance of axial flow hydraulic propeller turbine runner," 2015 International

Conference on Sustainable Energy Engineering and Application (ICSEEA),

Bandung, Indonesia, 2015, pp. 88-94, doi: 10.1109/ICSEEA.2015.7380751.