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T T P M: Echnology Ransfer AND Reparation of Anual
T T P M: Echnology Ransfer AND Reparation of Anual
TECHNOLOGY TRANSFER
AND
PREPARATION OF MANUAL
CHAPTER 12 TECHNOLOGY TRANSFER AND PREPARATION OF MANUAL
12.2.1 Overview
The extraction of promising micro-hydro power generation sites in Indonesia has
traditionally been conducted by a kabupaten(district)-related body based on information
provided by local residents in unelectrified areas. However, a full-scale survey of these
sites has often found the construction of a hydropower plant to be difficult because such
information, the nature of which is listed below, sometimes fails to appreciate the
negative factors described in brackets.
① Ease of securing the necessary head because of the presence of a waterfall (steep
topography makes it difficult to set up a settling basin and headrace, etc.)
For the present Study, it was recognized that there is a need for technology transfer with
emphasis on the following points to enable government offices to accurately extract
promising sites instead of depending solely on information provided by local residents.
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② Estimation of the discharge based on the rainfall level and size of the catchment
area and an on-site discharge observation method
⑤ Study method for the socioeconomic conditions and importance of the balance
between supply and demand
At some micro-hydro power development sites, the prevention of sediment inflow and
sediment disposal have not been taken into proper consideration and many power plants
at these sites have been destroyed by sediment inflow.
Under the present Study, the prevention of sediment discharge and sediment disposal
are the subject of intensive guidance and are described in detail in the manual.
• Water Turbine
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- Cross-flow type: turbine output (10 – 250 kW); effective head (4 – 50 m); flow rate
(100 – 820 litres/sec)
This turbine is designed by SKAT (T13 or T14 model) and its technical base is well
established with design data being fully available. It can be commended in the sense
that the design of a water turbine which is compatible with the actual on-site civil
engineering design conditions can be produced with relative ease. Some are already in
actual use.
- Reverse e pump type: turbine output (2 – 7 kW); effective head (4 – 20 m); flow rate
(4 – 130 litres/sec)
In the case of this type, the pump used for pumping water is reversed as a generating
turbine. Readily available pumps of this type in Indonesia are small with a generating
capacity of up to around 7 kW. This type of pump turbine can be applied at site where
the flow rate does not vary but cannot be applied, at sites where the flow rate
considerably varies The generator will be a direct-coupled induction motordue to small
size.
• Generator
As explained in clause 11.5.5.,the speed of water turbine with dummy load type speed
governor hardly increases and does not reach to run-away speed even in case the full load
is cut off suddenly during operation due to the reason that the actual load is transferred
fully to dummy load. Therefore, the generator for diesel engine can be used.As explained
in clause 11.5.5.,the speed of water turbine with dummy load type speed governor hardly
increases and does not reach to run-away speed even in case the full load is cut off
suddenly during operation due to the reason that the actual load is transferred fully to
dummy load. Therefore, the generator for diesel engine can be used.
- Synchronous generator (for Cross flow type water turbine: under license from
European manufacturer: 380/220 V, 1,500 rpm, 12 – 250 kVA, with a brushless exciter
and automatic voltage regulator) ). As these are manufactured with several capacities in
Indonesia, the selection of a standard type of this generator makes procurement quick
and easy
• Speed Increaser
The use of an ordinary hydraulic governor which regulates the rate of water flow by
automatically moving the guide vane is impossible for a small water turbine because of
its prohibitive high price. Accordingly, a dummy load type governor which is cheap and
already used in Indonesia should be opted for. The control part, which is equipped in
one substrate, is furnished in ELC type panel for synchronous generator or IGC panel
for induction generator. . It is strongly requested for proper operation to select either
type carefully because the excitation system of both kind of generator is completely
different. Because of the use of a thyrister for ELC and trasister for IGC, the reaction
performance of this type is excellent for interchanging between consumer and dummy
load. This type of governor is the best choice for micro-hydro power generation despite
its shortcoming of the some energy consumption from generator output by the dummy
load. The performance of a dummy load type governor is judged to be good enough for
micro-hydro power generation as it is of static type without mechanical moving part.
• Control Panel
The recommended control panels are the ELC type and the IGC type (both of which are
equipped with a dummy load type governor) manufactured in Indonesia. Many of these
have already been used for micro-hydro power generation and no immediate problems
regarding their use are foreseen. The ELC type is used for a synchronous generator
while the IGC type is used for an induction generator. Each type is equipped with the
minimum range of devices and instruments (meters) required for a micro-hydro power
plant.
• Inlet Valve
The inlet valve is to control the water inlet to the turbine and such manual operation
butterfly valve with international standard of the sizes required for micro-hydro power
plant (MHP) can be procured in Indonesia and its simple manual operation ensures its
long life. The relevance of an inlet valve for micro-hydro power generation is debatable
because of its extra cost. However, it is judged that the use of an inlet valve is
preferable in view of better equipment maintenance, easy starting up and stoppage of
operation and better safety for operators, etc. Dummy Load Heater
The dummy load heater used for above speed governor is a simple air-cooled electric
heater which can be cut to achieve a suitable length corresponding to the capacity of the
dummy load. The dummy load is same in its construction but it is used as AC load for
ELC type and DC load for IGC type. The installation location of the dummy load
should be determined to ensure its efficient cooling. To be more precise, a separate
room with louvred window should be set up as described in Chapter 11.
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12.2.4 Transmission and Distribution Aspects
The PLN has well-established technical capability to handle 20 kV as well as 380/220
V distribution lines related to micro-hydro power generation and it is judged that no
problems exist in regard to transmission and distribution, including indoor wiring at
user premises.
o Yayasan Turbine Desa: This NGO is based in South Sulawesi Province and is
engaged in rural electrification based on technologies transferred by the GTZ
in the early 1990’s (particularly technologies relating to the manufacture of
SKAT-T3 turbines).
o EDEN: This NGO is based in Kupan in East Nusa Tenggara Province and the
teaching staff of an industrial college play a leading role in forest conservation
and rural development. It plans to assist rural electrification using micro-hydro
power as a new field of activity and participated in the OJT in collaboration
with the provincial government.
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③ Demand survey
③ Electrification plan
④ Design
① Detailed design
② Cost estimation
The construction work under the pilot project (micro-hydro power plant) by a local
contractor was supervised. The technical know-how required for the smooth progress of
the work was transferred.
The operation of the pilot plant, the test operation and inspection of which was
completed, commenced. Guidance was provided to ensure an appropriate operation
system based on the already established maintenance system and charge collection
system. The system to continue monitoring by local people without reliance on
outsiders was established by clarifying the check items for monitoring and actually
commencing monitoring work.
(7) Monitoring
The entire system of the pilot plant was evaluated from various angles, including
technology, maintenance and financial management
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12.3.3 Workshops
Various workshops were organized to extend the achievements of the OJT to a wide
range of people related to the pilot project. The timing of the workshops which
corresponded to the progress of the OJT is given below.
First Workshop: during the fifth field survey period (preliminary study and project
planning)
Second Workshop: during the second half of the sixth field survey period (detailed
design, work supervision and operation and maintenance)
Third Workshop: during the second half of the seventh field survey period (monitoring)
Fourth Workshop: during the eighth field survey period (system evaluation)
① Locations
Duration
- OJT during fifth field survey: 13 days between 24th June and 10th July, 2002
- OJT during sixth field survey (first half): from 30th August to 4th September, 2002
- OJT during sixth field survey (second half): from 24th to 28th October, 2002
- OJT during seventh field survey (first half): from 16th to 20th January, 2003
- OJT during seventh field survey (second half): from 20th to 23rd February, 2003
- OJT during eighth field survey: 5th and 6th June, 2003
② OJT Participants
Table 12-4-1 List of OJT Participants
Name Affiliation Remarks
2 Ilham “ “
4 Purwanto Kamurullah “ “
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6 Welem Sambolangi “ “
10 Abdullah “ “
12 Yunus Tandi “ “
13 Luther Pongrekun “ “
16 Okitavianus Dharma “ “
Rerung
17 Silas Kase “ “
- OJT during sixth field survey (first half): establishment of maintenance and electricity
charge (collection) systems; detailed design
- OJT during sixth field survey (second half): operation and maintenance; distribution
equipment; work supervision
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Theme Date Contents
Lecture on Planning
Wrap-Up Workshop
Wrap-Up Workshop
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Seventh Field Monitoring 16th ~ Monitoring
Survey
20th Jan.
(First Half):
2003
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12.5 PREPARATION OF THE MANUAL
12.5.1 Important Points for Preparation of the Manual (Knowledge Obtained Through
OJT, etc.)
The following knowledge as shown in Table 12.5-1 obtained through the OJT was
incorporated in the preparation of the manual.
The manual also intends to achieve the active use of locally procurable resources in
Indonesia (human resources, local materials and equipment made in Indonesia, etc.) and
its target scale of development is outlined below.
Effective head : 4 – 50 m
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Table 12.5-1 Knowledge Obtained Through OJT and Its Incorporation in the Manual
Knowledge Obtained Through OJT Incorporation in the Manual
Preliminary The concept of “catchment area” is not established. The definition of “catchment area”, calculation
Study method and relationship between rainfall and
discharge are described in detail.
There is no previous experience of extracting The method to extract candidate sites from a
candidate sites based on an existing topographical topographical map is described together with
map. important issues relating to site selection.
It is difficult to establish understanding of the The meaning of the correction factor for each
relationship between a measured flow value and type of flow velocity measuring method and river
correction factor for calculation of the average flow conditions is explained together with illustrations.
velocity.
There is insufficient understanding of how to A measuring method using locally available
measure the head and flow when a measuring simple measuring tools (such as a hose and float,
instrument is not available (inability to conduct etc.) and a recording method are introduced.
measurement without advanced equipment).
There is no previous experience of conducting a rural The necessary survey items in connection with
social conditions survey. electrification using micro-hydro power are listed
in the form of a survey sheet.
Generation Knowledge of the functions of each civil engineering The functions of each structure and important
Plan structure and of the selection of a desirable location issues relating to the selection of a location are
is insufficient. described.
Knowledge of the selection of generating equipment Procurable equipment in Indonesia and the
is insufficient. selection method are introduced.
Detailed Theoretical understanding of the basic structures of Only basic theoretical issues are described and
Design various civil engineering structures and the method basic dimensions are described in a manner which
to determine their dimensions is occasionally found they can be determined with the use of
to be difficult to achieve. diagrammes and tables.
Basic knowledge of detailed electrical and Only the minimum descriptions necessary to
mechanical design is insufficient. determine the specifications to be ordered are
given and the details of design are described in
the Annex.
Understanding of such detailed issues as the Basic issues for distribution planning are simply
selection of economical cables and the suitability of described. As the details are determined on a case
transformer installation for power distribution by case basis, it is recommended that the
purposes is insufficient. cooperation of the local PLN, etc. is obtained.
Operation and Knowledge of items to be considered when deciding The items to be considered when deciding the
Maintenance the charge level, etc. is insufficient. charge level and the calculation method are
described using examples.
Kabupaten officials have no special difficulty in Concrete descriptions are given using examples
organizing people and preparing rules of of actual pages of an accounts book to ensure
Management, etc. because of their experience of transparent accounting practice.
village-based cooperatives but their knowledge of the
importance of accounting reports and need for
accounting transparency is slightly insufficient.
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Outline survey of the site; measuring of water flow and head; demand survey method and
important points
Chapter 4 Planning
Generation method; scale of generation; selection of installation locations of various structures;
supply and demand balancing method and important points
Chapter 5 Civil Engineering Design
Methods to determine the basic structure and main dimensions of each civil engineering
structure; important points for design
Chapter 6 Design of Electrical Equipment
Selection of generating equipment, mainly cross-flow water turbine or reversible pump turbine,
both of which are procurable in Indonesia; method to decide the items necessary to place an order
for equipment
Chapter 7 Design of Transmission/Distribution Equipment
Basic issues regarding transmission/distribution; design concept
Chapter 8 Estimation
For rough planning: simplified estimation using diagramme and table
For detailed planning: estimation items; quantity surveying; unit price; others
Chapter 9 Work Management
Key points for work management; schedule management; quality management
Chapter 10 Operation and Maintenance
Items to be included in the operation manual; maintenance guidelines
Chapter 11 Plant Management
Composition and roles of the management body; charge system; accounting system; others
The traditional technical problems referred to in Chapter 12.2 were overcome through
technology transfer and the following activities are now being conducted in Kabupaten
Tana-Toraja and East Nusa Tenggara Province.
In East Nusa Tenggara Province, EDEN, a local NGO, is conducting the following
study entrusted by the provincial government.
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• Target areas : Flores Island and West Timor
During the eighth field survey, the JICA Study Team checked the results of the survey
conducted by EDEN at the respective sites. It was confirmed that the accuracy of these
surveys has reached an acceptable level even though the survey results had some minor
errors.
The importance of the maintenance and organized management of a power plant was
fully understood through the OJT and the positive effects of such awareness are visible
with the management and maintenance of the pilot plant as described earlier.
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<General Description> <General Description> Houses are relatively Some households have
Traditional houses are A few households have scattered. Many houses purchased a PVC.
relatively concentrated. purchased a PVC or are of lower quality.
Villagers have high small generator for
expectations for personal use. The
electrification. economic situation is
better than that of most
villages on the island.
General Small irrigation An intake weir and The target river is Irrigation facilities
Situation channels exist. water channels for relatively steep and exist.
irrigation exist. MHP is feasible at
other sites.
Evaluation The survey results are The survey results are There is a slight Given the capacity of
and accurate. The relatively accurate. In problem regarding the the existing channel,
Instructions installation of a view of the possible introduction of a the maximum flow will
Made transformer has been widening of the existing headrace at the site be approximately 0.15
instructed in view of water channel, surveyed by EDEN. An m3/sec.
the long distribution however, the Q value in instruction was given to
length. parenthesis should be change the planned
more suitable. The river location to the upstream
has a high level of where a headrace can
sediment discharge and be more easily
there is a large inflow introduced.
of sediment into the
existing irrigation
channels. An
instruction was given to
consider sediment
disposal.
Overall Evaluation Results
Out of the four surveyed sites, irrigation channels, etc. already exist at three sites. Measuring of the head and the
selection of the plant location, etc. at these sites have been accurately conducted based on knowledge acquired through
the OJT. The water flow at a new sites has been accurately measured but the ability to select the optimal channel route
(particularly selection of the headrace route) was found to be slightly insufficient. In addition, the numerical checking
of household income, etc. is also insufficient. (This is due to a lack of experience and the accumulation of experience
under the on-site guidance of an expert is important.)
Note: The figures in parenthesis are the survey results of the JICA Study Team.
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